cat-c6_6-c4

C6.6 C6.6 & C4.4 C4.4 with wi th ACERT® Technology

May 2005 - Page 1 Caterpillar Confidential: Green

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From the library of Barrington Diesel Club C6.6

1

Important 





The product training information is distributed for inf ormational purpos es only. It It is not to be const rued as creating creating o r becoming part of Cat Cat contractual or warranty obligations This presentation presentation mus t be printed in notes page format, with the speaker speaker not es showing , which c ontain essential essential additional inform ation. The appropr appropr iate servic servic e literature, should always always be the final authority and source of information


C6.6

2

C6.6 C6.6 & C4.4 C4.4 ACERT ACERT Benefi Ben efitt s Installed Package Engine Size Cooling Pack

Refinement 3 dBA Noise Reduction Reduction Quality of Noise Low Vibration

Cost of Ownership Fuel Economy Service Period

Ratings Environment

Power Torque

Emission compliant Filtration

Product Functionality Electronic Electronic Functionality Machine Integration

Cold Start Fuel Fuel Compatibilit Compatibilit y PTO

May 2005 2005 - Page 3 Caterpillar Confidential: Green

C6.6

3

Electroni cally assisted 

To create…. – Lower emmisions Better fuel cons umption – Better – Versatile control


C6.6

4

S/N Prefix Nomencl Nomenclatur ature e

3054E

3056E

3054C

304

35 356

33 334

666

444

CRX

CPT

CRS/G4D

???

C4E

Ind. nd. Mach.

C6.6

C4.4


C6.6

5

Tier 3 Dates Dates and Rati Rating ngs s January 2008 2008 Emissions

January 2007 2007 Emissions

January 2006 2006 Emissions

260 – 330HP* 330HP*

C6.6 120 120 – 250H 250HP P

C4.4

68 – 140H 140HP P

100HP

175HP *Application Specific


•For ratings above 250hp see ERM for detail of applications and usage •Ratings above 286hp/213kW are not currently planned with Stage 3a emissions certification •Revise the slide for USA APA

C6.6

6

Features 4 Valve Head

ECM

Timing Cylinder Block

Crankshaft Fuel System May 2005 - Page 7 Caterpillar Confidential: Green

C6.6

7

Engine Features 

6.6 Lit res – Same Bore/Stroke as 3054C  105mm/127mm – New Bl ock for 6 cyl  Scalloped  Ribs 

Noise Attenuation

Closed Top Deck  Parent Bor e  Oversized Pisto n Service Solution 


The 6 cylinder engine now has a capacity of 6.6 litres. The Bore and stroke of the engine is in line with 3054C at 127mm stroke and 105mm bore. The new six cylinder block, which is 10.5mm longer than the 1106C, has a scalloped crank case with extra ribbing These features give a more ridged structure with a lower noise attenuation. The block is of a closed top deck configuration with 120mm spaced, non siamese, bores. The production block is liner less and has a new standard of bore finish (TD522). Oversized pistons will be the service solution for overhaul. (0.5 – 1.0 mm) Will be available after 2007. .

C6.6

8

Piston Design 

Pistons – Two Types  Gallery Cooled  Non - Gallery Cooled – Al uminium – Quiescent Bowl Design – New Rin g Pack  Improved Oil Control – Graded Rods for Pist on Protrusion – Square Boss t o the Front


Two types of piston are used, gallery cooled and non-gallery cooled. The squared boss on the inside of the piston is fitted facing towards the front of the engine. A new ring pack combined with the new bore finish (TD522) gives good oil control. Piston protrusion is controlled by use of graded rods. The piston is made of a low expansion aluminium incorporating a Quiescent bowl design. This design of combustion bowl allows the use of multiple injections.

C6.6

9

6 cyl. Connecting Rod 

Connecting Rods – Fracture Split  Removal fr om th e Top – Notches  Bearing Alignment  Not Int erchangeable Top to Bottom – 3 Lengths for Piston Protrusion – Al ways use New B ol ts – Dimples for Orientation

Dimple

Dimple

Notch

May 2005 -Page 10 Caterpillar Confidential: Green

There are three lengths of con rod to adjust the piston height. The con-rods are fracture split at an angle to facilitate their removal from the top end of the block. These fracture split con-rods have conjoined notches to locate the big end bearings shells. The bearing shells are therefore not interchangeable between cap and rod. It is recommended that the con-rod bolts are never reused. For torque method and load refer to the relevant workshop Manual The conrod and cap have dimples on them to identify correct orientation.

C6.6

10

6 cyl. Crankshaft 

Crankshaft – Balanced Steel For ging  Inducti on Hardened – Larger Mains Diameter  84mm, 8mm Increase – Larger Rod Diameter  72mm, 9mm Increase – 15mm Bearing Overlap Increase  Withstands Higher Torsional loads – Lead free Bearings – 100% Front PTO


The fully balanced crankshaft is a steel forging. For increased power and improved bearing life, the following improvements have been made The main journals are now 84mm in diameter an increase of 8mm over 3054C The big end pins are 72mm an increase of 9mm over 3054C These increases in bearing diameters gives an increase of 15mm in bearing overlap over crankshafts on previous engines of this size. All bearing surfaces are induction hardened as are the fillet radii. All bearings are lead free. The crank nose has been re designed to allow `100% power take off.

C6.6

11

Thrust Bearing 

Crank Thrust Bearing – #5 Main – Fitted into the Block  Faces the Crank – Squared ends for prop er installation – Al uminium Bas e - Lead Free


The crankshaft thrust washers are fitted either side of the No 5 main bearing position The thrust washers are fitted into the block ensuring the bearing face is towards the crankshaft. The squared off ends fit into recesses in the main bearing saddle and bearing cap. The thrust washer bearing face is of a lead free aluminium base. The main bearing caps are tightened using the torque and angle method. Refer to relevant workshop manual for details of load and angle.

C6.6

12

Isolated Sump Sump connected to block via isolator plate.  Gives benefits of noise reduction. 



Isolator plate


C6.6

13

Rear End Oil Seal Fitting


C6.6

14

Main Bearing Caps 

Bearing Caps – Installation  Use Torque and A ngle Method  Details in D&A Manual


The main bearing caps are tightened using the torque and angle method. Refer to relevant workshop manual for details of load and angle.

C6.6

15

Cylinder Head Details 4 Valve per Cylind er  Centered Inject or  Non-Sleeved Inject or Bores  Service 

– Non-Serviceable Valve Guides and Seats


This close up shows 4 valves per cylinder. The central position for the injector. The rocker pedestal location bolt holes. The valve stem seals are of the same material and design as the 3054C but of a smaller diameter to suit the smaller valve stems. Seals are colour coded for inlet & exhaust. The head design does not use serviceable valve guides or seats. The head face cannot be machined. An adaptor is required to be used with current valve spring compressor.

C6.6

16

Head Bol t Torque Sequence 11

7

3

14

10 6 2

8

4

12 13 9 5 1


The tigh tening sequence is fro m the outside to the centre of the head, as shown above. The cylinder head and MLS head gasket are dowel located to the cylinder block. The head is tightened using the torque and angle method. Refer to the relevant workshop manual for the torque and angle recommendations. There are 14, 16mm bolts. The bolts are 118mm long.

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17

Head 

Head – Multi -Layered-Steel (MLS) Head Gasket – Fourteen - 16mm bolts  Single Use – Torque and Angle Tightening Method


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18

Rocker Ass embly Inlet

Bridg e can be inst alled either way  Single Bolt p er Rocker Lever  Lash settings the same for Inlet and Exhaust  Injector s c an be replaced without removing Rockers 

(Long)

Exhaust (Short)


The close up of the rocker levers and valve operating bridge piece. The bridge pieces can be fitted either way round. The bridge piece has one elongated hole. This allows for a variance in valve positioning in the head. The rocker levers are located by a single bolt per rocker lever. The longer lever operates the inlet valves Valve clearances are set using a new method. Refer to the relevant manual. Valve clearances are the same for inlet and exhaust. Rockers need not be removed but can be manipulated to allow removal of injectors.

C6.6

19

6 cyl. Oil Pump Servic ed as Assembly  Left Hand fil ter to Right Hand f ilter requires additional piping 

Pressure Relief Valve


To move the oil filter option from the LHS to the RHS of the engine requires extra piping to be introduced into the crankcase area. The oil flows to the cooler via internal galleries. From the cooler the oil passes to the lube oil filter and then on into the oil feed galleries.

C6.6

20

Timing Case 

Timing Case – Increased Clearance for Idler Hub access – PTFE Crank Seal wit h du st seal – New Seal Recommended if Timing Case is r emoved – Use “ dummy” Sleeve when fron t Pulley is Removed

Camshaft locating pin boss

Idler Hub Location

Integral front oil seal to ensure seal to c rank alignment May 2005 -Page 21 Caterpillar Confidential: Green

Cam locating position will be on the right hand side of the gear viewed from the front. Idler hub location in timing case is larger for clearance of the hub and gear installation (an alignm ent tool is r equired to c entralise the case). Front oil seal mounted in the timing case for exact alignment to crank. The front seal is of PTFE with dust seal. The seal is supplied with a fitting sleeve, which must remain in the seal until fitted. A dummy sleeve should be fitted in the seal when front pulley is removed. The correct installation tool must be used to ensure correct alignment. It is recommended that if the timing case is removed, a new oil seal is fitted.

C6.6

21

Timing Case 

Timing Case Align ment Tool must be used – Al lows Idler Gear and Hub t o be inst alled as an assembly

Cam Gear Ali gnm ent


•Tool aligns the timing case. •This allows the idler gear and hub to be fitted as an assembly

C6.6

22

Idler Gears 

Two Types – Bronze – Double Needle – Dependant on PTO requirements.


C6.6

23

Camshaft Thrust Washer 

Two Different Camshaft Thrust Washers – One Notch  PTO mount ed RHS  Greater than 35Nm Torque – Two Notches  Al l ot hers

Notches

Two Notch Version May 2005 -Page 24 Caterpillar Confidential: Green

There are two camshaft thrust washers available. One has two location notches, as shown, the other only has one. The one notch washer is used where there is a requirement for a PTO mounted on the RHS requiring in excess of 35Nm torque.

C6.6

24

Static Timing 

Pinnin g th e Crank to #1 TDC – Notch in Crank – Servic e Tool A vailable – Remember to Remove Pin

TDC access point


To facilitate setting the engine to an accurate, No I cylinder, TDC a timing pin is available. Remember to remove the pin and replace the blanking screw.

C6.6

25

Camshaft Timing 

Camshaft Al ignment Tool – Not a Tight Fit – Ease of Ass embly


• Use the camshaft alignment tool to locate the camshaft. •The tool is only used to locate the gear and is therefore not a tight fit. •This allows the cam gear to move slightly when fitting the Idler gear easing the assembly.

C6.6

26

Crank Speed/Timing New Sensor  Located at Rear of Bloc k  Reads too th wh eel attached to the Crank 


The toothed timing disc is of a pressed steel manufacture. The design is different to that used on the previous electronically controlled engines.

C6.6

27

Fuel System Overview 

Caterpillar Fuel System usin g co mmon rail technology – Low Pressure  300kPa (43 PSI)  20 Micron Primary Filter  2 Micro n Second ary Filter  Fuel Cooler Required on some arrangements – High Pressure  Up to 160 MPa (1600bar - 23,200 PSI) 

Fluid p enetration safety hazard.

Hardened Fuel Lines  External Fuel Manifo ld 


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28

How small is a Micron?


C6.6

29

Fuel System Handling IMPORTANT! 

Cap all fuel p assages Immediately after removal



Do Not “ Blow Out” or “ Wash Out” any fuel passages



Place removed p arts in clean area



Do Not pre-fill filters





Remove packaging and pro tective caps immediately before installation Fuel Lines cannot be reused


C6.6

30

Low Pressure Fuel System


The schematic above shows us the layout of the High pressure fuel system used by C4.4/C6.6 electronically controlled engines. Fuel is placed through the primary filter, forwarded onto the transfer pump which moves fuel onwards into the cooling chamber of the ECM, (Where used). For further and more substantial cleanliness, fuel is passed through a secondary filter and passed clean onto the High pressure pump.

C6.6

31

High Pressur e Fuel System Injectors

High pressure fuel rail

High pressure fuel pump


The pressure of fuel is raised and transferred into the High pressure fuel rail. Finally each Electronically actuated injector is branched from the rail.

C6.6

32

Fuel Pump 

Two Pumps

Lube Oil Feed

– High Pressure – Transfer 

HP Pump Lubricated by Engine Oil – Longer Life

Pump Speed/Position Sensor

Transfer Pump


The fuel pump comprises of the transfer pump and high pressure pump in one unit. The high pressure fuel pump is lubricated by engine oil. This gives an extended pump life compared to pumps lubricated with fuel. The transfer pump does not require a lift pump but does require priming. The method of priming is either by hand pump incorporated into the primary filter head or by an electric priming pump.

C6.6

33

High Pressure Fuel Pump Fuel in to HP Pump Fuel Leak off to Tank

From Secondary Filter To Fuel HP Manifold To Secondary Filter

From Primary Pump Speed/Positio n Sensor

Filter


The high pressure fuel pump is mounted on the LHS of the engine. The pump is locked, for timing purposes, prior to being fitted to the engine. (If the pump is not locked, it should be returned to the authorised outlet.) This ensures that the delivery strokes from the pump are in phase with the injector deliveries. Always refer to the manual for the correct removal and re-fitting procedure. The high pressure fuel system is self bleeding. Fuel li nes must n ever be cracked to purg e air. When the pump i s replaced the feed pipe to th e fuel manifo ld mus t also be replaced. Fuel is directed to the fuel manifold and from there to the injectors.

C6.6

34

Fuel Pump Stroke in phase with Injection  Self Bleeding 

– Do Not Crack lines to bleed

Lock Pump BEFORE removal  Replace HP Fuel Line when Pump is removed 

– Check Clips

Two Cams – 2 or 3 lobes each  Solenoid adjusts rail pressure and return to tank  Needs t o be Timed 

– Lock in Place BEFORE Removal


The 6 cylinder high pressure pump has two three lobe cams. The 4 has two two lobe cams. This enables it to deliver six pumping strokes per pump revolution The solenoid valve determines fuel rail pressure and fuel returned to tank. Excess fuel is returned, via the pump leak off, to the fuel tank Fuel enters the HP pump and is directed via non return valves to the two plungers On the delivery stroke of a plunger a percentage of the fuel is delivered to the fuel manifold, again via a non return valve. The volume of fuel delivered to the fuel manifold is dependant on the position of the solenoid valve. Fuel in excess of that required to maintain the desired pressure in the fuel manifold is re-circulated. Some re-circulation of fuel takes place within the pump, The remainder of the fuel is returned back to the fuel tank.

C6.6

35

Fuel Pump Function Pump Raises Pressure  ECM tells Injector t o Fire  Rail Pressure Drops  ECM Detects Press ure Drop 

– Sensed by Fuel Rail Pressure Sensor 

ECM tells Pump Solenoid to Increase Volum e – Al so tel ls Pump Solenoi d t o Spill fuel once pressure is reached



Do it Again!


As the injector solenoid is actuated a pressure drop occurs in the fuel manifold. This pressure drop is registered by the ECM from a signal sent by the pressure sensor in the fuel manifold. The ECM sends a requirement for an increase in delivery volume from the pump to return the rail pressure to the desired pressure. When the pressure sensor informs the ECM that the desired pressure is correct the ECM then causes the solenoid valve on the pump to reduce fuel volume. This cycle takes place every time an injection takes place. It is therefore important to phase the pump delivery to injection sequence and occurrence to ensure that fuel manifold pressure does not drop too much.

C6.6

36

Transfer Pump Driven by High Pressure Pump  Draws Fuel throu gh Primary Filter  Output Pressure 

– 300 to 400 kPa – 43 to 58 PSI 

Transfer Pump Primed by Priming Pump – Hand or Electric – No Lift Pump Requir ed


The transfer pump is driven from the rear of the High Pressure Pump drive shaft. The pump has the capacity to create both negative and positive pressures. It draws the fuel (negative pressure)into the pump, via a 20 micron primary fuel filter The pump then delivers the fuel, at between 300 – 400 kPa, to the secondary filter.

C6.6

37

High Pressure Fuel System 

Do’s & Don’ts

Fuel Manifol d

– Do Check f or l eaks – Do Not Loosen HP Connecti on with Engine Running – Do Replace HP Pipes After they are Loosened – Do Replace ALL Hp Pipes if new manifold is Installed – Do Not Force Pipes to Fit – Do Cap Manifold and Injector Connections Immediately when HP Pipe is removed

Injector Lines

Feed From High Pressure Pump


High pressure pipe connection s must n ever be loosened when the engine is running or being cranked. High fuel pressure is always present throughout the high pressure system when the engine is running or being cranked. All h ig h pressure pip es must be replaced every ti me they are dis turb ed. All pipes must be renewed when a new fu el manifo ld is fi tt ed DO NOT bend the pipe for any reason as it has been internally hardened. Any attempt to bend the pip e coul d rupture this pr ocess whic h cou ld lead to a very high pressure leak. Do not fit a fuel pi pe which i s damaged in any way. New fu el pipes are supplied sealed in pro tective packaging. This protection should remain on the pipe until just before the moment of fitting.

C6.6

38

High Pressure Fuel System 

Do’s & Don’ts

Fuel Manifol d

– Do Remov e HP Cap just befor e installation – Do Keep your Work Ar ea Clean – Do Think about Cleanlin ess when worki ng on HP System – Do Make Sure all Clip s and Clamps are tight and in position

Injector Lines

Feed From High Pressure Pump


High pressure pipe connection s must n ever be loosened when the engine is running or being cranked. High fuel pressure is always present throughout the high pressure system when the engine is running or being cranked. All h ig h pressure pip es must be replaced every ti me they are dis turb ed. All pipes must be renewed when a new fu el manifo ld is fi tt ed DO NOT bend the pipe for any reason as it has been internally hardened. Any attempt to bend the pip e coul d rupture this pr ocess whic h cou ld lead to a very high pressure leak. Do not fit a fuel pi pe which i s damaged in any way. New fu el pipes are supplied sealed in pro tective packaging. This protection should remain on the pipe until just before the moment of fitting.

C6.6

39

Fuel Pressure Relief Valve 

Protects System from Over-Pressure

High Pressure Relief Valve

– Opens at Const ant Pressure of 160 MPa (23,000 PSI) – Withstands Spikes to 190 Mpa (27,500 PSI) 

Returns fuel to Tank


The primary function of the fuel pressure sensor is to constantly monitor rail pressure. If it detects rail pressure above 160 MPa diagnostic code 157-00 will be displayed and the engine will default to ‘limp home’ mode. The high pressure relief valve protects the high pressure fuel system from excessive pressures. The valve will operate with a constant pressure above 160 MPa.(1600 bar) but allow pressure spikes of up to 190MPa.(1900bar) The fuel passing the pressure valve will be returned to the tank and will be at a very high temperature. After rectifying the cause of excessive pressure it will then be necessary to replace the pressure valve.

C6.6

40

Fuel Return from Head 

Excess Fuel Retur ned to Transfer Pump

Fuel

– Not High Pressur e

from

Return Head LIne


The injector leak off is a gallery return from the injectors in the cylinder head.

C6.6

41

Injector Function ECM Energizes Injecto r  Valve Lifts  Fuel Flows to Nozzle 

Solenoid energized

Valve

To nozzle


When the solenoid is energised, start of injection, the valve lifts. The fuel manifold pressure now passes below the valve and down to the nozzle. When the solenoid is de-energised the valve closes removing fuel manifold pressure from the nozzle. The closing nozzle needle forces the fuel to pass the upper face of the valve into the leak off drilling in the injector body. The leak off fuel then passes via the gallery in the head to the return to the fuel tank.

C6.6

42

Injector Function Injector De-energizes  Valve Closes  Unused fuel flow s back to Transfer Pump via passage in the Head 

Solenoid deenergized


When the solenoid is energised, start of injection, the valve lifts. The fuel manifold pressure now passes below the valve and down to the nozzle. When the solenoid is de-energised the valve closes removing fuel manifold pressure from the nozzle. The closing nozzle needle forces the fuel to pass the upper face of the valve into the leak off drilling in the injector body. The leak off fuel then passes via the gallery in the head to the return to the fuel tank.

C6.6

43

Fuel Injector Connections 

Two Types – High Pressure Fuel – Electrical  Three Connectors thru Valve Cover Base


High pressure and electrical connections to the injectors.

C6.6

44

Fuel Injector 

Do’s and Don’ts – Do Use Proper Torque on Electrical Connection  Servic e Tool A vailable – Do Finger Tighten all Clamps and HP Lines, First, then torque properly – Do Cap the Injector Immediately After Removi ng HP Fuel Li ne – Do Make Sure th e O-Ring and Copper Washer are in place  Do Not Re-use O-Ring or Copper Washer


Electrical connections to the solenoid operated injectors can be easily damaged. Do not over-tighten. Use the correct tool and to rque found in the manual. When replacing injectors, finger tighten the injector clamp, align the high pressure pipe and finger tighten the nut, tighten the injector clamp to its correct torque. Fully tighten the high pressure pipe nuts using the correct tooling and torque. DO NOT bend the pipes. Remember to ensure there is only one copper sealing washer on the injector nozzle. Replace the injector pipe, copper injector washer and ‘O’ ring when replacing the injector. The injector serial number and confirmation code will be used for trimming the injector. The 3d bar code in the center is used in production. More about injector trimming later on in the training.

C6.6

45

Fuel Injector 

Do’s and Don’ts – Do Writ e down the Injector Serial Number and Confi rmation Code before you install th e Injector – Do use Cat ET to Prog ram ECM with pr oper Injector Trim File – Do Look for the Trim File CD in the Injector Box


Electrical connections to the solenoid operated injectors can be easily damaged. Do not over-tighten. Use the correct tool and to rque found in the manual. When replacing injectors, finger tighten the injector clamp, align the high pressure pipe and finger tighten the nut, tighten the injector clamp to its correct torque. Fully tighten the high pressure pipe nuts using the correct tooling and torque. DO NOT bend the pipes. Remember to ensure there is only one copper sealing washer on the injector nozzle. Replace the injector pipe, copper injector washer and ‘O’ ring when replacing the injector. The injector serial number and confirmation code will be used for trimming the injector. The 3d bar code in the center is used in production. More about injector trimming later on in the training.

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46

Cleanliness Thoroughly clean equipment b efore disassembling  Use onl y NEW protecti ve caps to seal fuel connections  Replace HP Fuel Li nes if they h ave be loosened 


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47

Fuel Injection Serviceability NEVER loo sen high p ressur e pipes when engine is running! 23,000 PSI  Use Electronic Service Tool to Troubleshoot Injector Problems  Injectors have no serviceable parts. 

– Warranty w ill on ly be paid with evidence of the correct tests. 

Pump Solenoid is no n servic eable. – If the solenoid is r emoved the whole pump assembly must be replaced.


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48

Fuel Injection Serviceability Transfer pum p is a serviceable item, separate from High Pressure pump .  Speed senso r is servi ceable. 


C6.6

49

Smart Wastegate On Al l Variable Speed Engines  Controls Wastegate Actuator  Optimizes Engine Performance  Driven by PWM Signal fro m the ECM  Servi ce as an Assemb ly 

Smart Wastegate Controller

– 12 or 24 volt


A smart wastegate is fitted to all variable speed engines. It controls the pressure applied to the mechanical wastegate actuator. Smart wastegate gives flexibility to match boost pressure requirements at both part load and full load conditions over the entire operating range. Optimised emissions for any torque curve. Optimised engine performance at non emissions points – i.e. reduced exhaust temp. The controller is serviceable only as an assembly, there are different part numbers depending supply voltage (12 & 24volts).

C6.6

50

Wastegate Actuator 1 mm Total Travel  Refer to Servi ce Manual f or Adjustment Procedure 


Care must be taken when setting up the Smart Wastegate actuator. The fitting of a new, adjusted or replacement actuator requires mandatory checking of settings as shown in the service manuals. If the Wastegate does not operate at the correct pressure, it can effect the engine performance. High pressure setting will result in engine de-rate. Low pressure can cause black smoke and may also result in engine de-rate.

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51

Smart Wastegate Schematic Tells Solenoid How much Pressure To Pass

Looks at: Desired Speed Load Boost

Intake Manifol d Pressure (Boost)

Intake Manifol d Pressure (Boost)


With a normal Wastegate turbocharger as the exhaust gas volume and temperature increase so does the turbo boost pressure. At a predetermined pressure the boost air pressure over comes the spring load and the Wastegate valve (D) opens venting the gas into the exhaust outlet, thus controlling the turbo boost pressure. In the ‘Smart Wastegate’ the pressurised air passes to the Wastegate Actuator (C) via a control valve (B). This valve is normally open allowing the air to vent to atmosphere. The spring in the Wastegate Actuator (C) is of a lower compressive load than in the standard Wastegate, therefore it is possible to overcome the spring and open the Wastegate at a lower pressure output from the turbo. By operating under the control of the ECM (A), the boost pressure can be controlled throughout the operating range of the engine.

C6.6

52

Glow plugs Installed on ALL Engines  Improved 

– Sheathed Element

850 °C in 4 Seconds  Controlled b y ECM 

– Via OEM Relay

1 - Early Glow plug 2 - Improved version.


C6.6

53

Electronic Components Intake Air Temperature Sensor Coolant Temperature Sensor

Intake Manifol d Pressure Sensor Fuel Rail Pressure Sensor ECM

High Pressure Fuel Pump

Pump/Cam Speed/Position Sensor

Crank Speed/Position Sensor Oil Pressure Sensor


C6.6

54

Engine Wiring Harness Both Connectors and Harness are servi ceable  Pump Connector Serviced by Pigtail 


Harness serviceablit y Entire harness only needs to be replaced if ECM connector is broken. Individual connectors are available in the parts system. Pump connector is serviced by pig tail. Two general purpose connector kits are available. One for DT connectors and one for AMPSeal. All connectors use a common crimp tool. Connector seals are available as service items. The harness ties/clips are available. The three injector harnesses under valve cover are serviced separately as assemblies. It is essential these are properly secured. Reminder – Do not connect wiring to injector lines.

C6.6

55

Engine Wiring Harness 

Harness Do’s and Don’ts – Do clip th e harness – Do Not Force Connector s  Keyed to ensure Correct Connection – Do Not use “ Electrical Grease” – Do make sure seals are in go od cond iti on



Diagnost ic Connector – Cat Machine Engines - No – Industrial Engines - Yes


We have a very ‘Fault Tolerant’ extremely robust and reliable system. Inevitably after many years service, faults may occur. Traditionally, if the problem is ‘Electrical’, wiring / connectors are most likely to be the cause. Shorts / open circuits / high resistance connections, can be caused by any combination of corrosion / abrasion / burning / vibration / fatigue and ‘liquid ingress’. Make sure all seals are correctly positioned. Blanking plugs must be fitted on any unused pins, to prevent any liquid ingress.

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56

On Engi ne Components ECM Cam

Pump

Intake Air Crank Coolant Oil Smart Wastegate Solenoid Diagnostic Connector

Fuel Rail

6 EUI Injectors

Intake Air


C6.6

57

ECM ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


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58

A4-E2 Fuel Cooled (ECM) 4mm Allen Key Fuel Flow ‘in’

J1 ‘Customer’ Connector

Anti-Vibration Mounts

J2 ‘Engine’ Connector

Fuel Flow ‘out’ Ground Strap


Earth strap and anti-vibration mounts are serviced separately. New anti-vibration mounts should be used when replacing the ECM. Note: Air cooled ECM’s are also used.

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59

A4-E2 Electronic Control Module (ECM) 

ECM Cont rol s: – Fuel Pressur e – Speed Governing – Ai r/Fu el Rat io – Start/Stop Sequence – Engine Protection Devices/ Diagnostics


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60

A4-E2 ECM Voltages/Current 

Nominal battery suppl y vol tage 9-32 volts – Expected voltage range/curr ent draw…  12V sys tem / 9-16 volt s / Max 30 Amp s (8mA ‘Sleep’)  24V sys tem / 18-32 volt s / Max 15 Amps (10mA ‘Sleep’)


C6.6

61

A4-E2 ECM 

Do Use the proper to ols to t ighten th e ECM Connector Screws – 6 Nm (4.4 lb-ft )



Do Use the ‘Test ECM’ Feature when trou bleshootin g the ECM


C6.6

62

Temperature Sensors ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


C6.6

63

Temperature Sensors 

Thermistor sensing devices – Resist ance varies with temperature – As tem per atu re i ncreas es i ts resistance decreases



Passi ve Sensor – Does not need it’ s own pow er supply


C6.6

64

Temperature Sensors Negative Temperature Coefficient (NTC)

2,500 ) e c s n a t m s h i O s e R (

1000 20 C

Increasing Temperature


C6.6

65

Temperature Sensors Thermistor Ground Pin No 2

Signal Pin No 1


C6.6

66

Temperature Sensors 

Engine Coolant Temperature Sensor – Used for engine prot ection, Warning/Derate/Shutdown



Intake Manifold Air Temperature Sensor – Used for engine pro tectio n, Warni ng/Derate – Smoke limitin g



Both Used for – Cold Start Strategy – Data Link Informati on


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67

Diagnostic Example 4.8

110-3 Signal shorted t o a high voltage or Open Circuit Very cold Temp Warning Temp

S T L O V

Start Derate Temp Shutdown Temp

0.2

110-4 Signal short ed to a lo wer volt age Temperature


Example given is engine coolant temperature sensor. Range, -40 to 150C Range, -40 to 300F Intake manifold temperature sensor has a different range and will give different diagnostic codes.

C6.6

68

Pressure Sensors ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


C6.6

69

Pressure Sensors Intake Manifold Pressure Sensor

Oil Pressure Sensor Fuel Rail Pressure Sensor


C6.6

70

Fuel Rail Pressure Sensors 

Fuel Rail Pressure Sensor – Determines Fuel Rail Pressure – Continu ous Operating Pressure 200 Mpa – Maximu m w itho ut damage, 260 Mpa (burst at 320 Kpa) – Temperature Range, -40º to +160ºC – Sensor has M12 x 1.5 Thread – Requir es Special ‘Crus h’ Washer for Sealing – Ensure there is n o Rail Pressure before removal – Servic ed as a Kit w ith ‘ Crush’ Washer


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71

IMA Pressure Sensors Intake Manifold Air Pressure Sensor  Measures Manifol d A ir Pressur e 

– Used to calculate air/fuel ratio – Used for smoke limiti ng strategy – Measures atmos pheric pressur e on “ key-on” – Servic ed as a Kit w ith O-ring


Atmospheric pressure is measured when the ignition is first switched on. If the atmospheric pressure changes (I.e, if the engine moves uphill), the engine will not de-rate until switched off and on again.

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72

Oil Pressure Sensors 

Engine Oil Pressu re Sensor – Used for engine protecti on, Warning/Shutdown – Provides sign al for pressure gauge, via the ECM – Servic ed as a Kit wit h O-Ring


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73

Pressure Sensors Integrated circui t  Capacitive sensor  Voltage outpu t varies with pressur e  Sensor con ditio ns the signal voltage output to the ECM  Act iv e Sensor (Needs a external power suppl y) 


C6.6

74

Speed/Timing Sensors ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


C6.6

75

Speed/Position Sensors 

Two speed/positio n sensors – Crankshaft - Primary – High Pressur e Fuel Pump - Secondary



Two Wire ‘Hall Effect’ – Produce Condit ioned Square Wave



Engine will Run if the Primary sensor f ails – ‘Lim p Home Mode’ - 1200 rpm Max



Engine will Not Shutdo wn if Secondary sensor Fails – Cannot b e re-started if the engine is st opped.


The toothed timing disc is of a pressed steel manufacture. The design is different to that used on the previous electronically controlled engines, in that now a wide tooth is used as the reference point.

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76

Crank Speed/Timing 

59 Teeth + 1 Wide tooth – 6º Between teeth

Wide tooth “ tells” ECM Crank Positi on  Teeth point to Nose of Crank  Use proper th read loc k adhesive w hen re-using screws 

Dowel Hole


The timing disc has 59 + 1 wide tooth. This gives 6° between teeth except where the gap has not been cut. This larger tooth will generate a different signal in the speed sensor. To re-fit a new disc pass it carefully over the rear seal face and engage it on the location dowel. Ensure the teeth point toward the nose of the crankshaft. The timing disc is secured with three setscrews. If these are to be re-used, the correct thread lock should be used as specified in the manual.

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77

HP Pump Speed/Position Sensor

Speed / Timing Sensor

Speed / Timing Sensor ‘Target’ 36 Teeth


• When the pump is renewed the feed pipe to the fuel rail must also be renewed.

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78

Hall Effect Sensor 

Produces a condi tioned square-wave signal

Old

New

Signal Output Waveform Crank Speed/Position Target


Using a hall effect sensor gives a sharp, square wave form, giving more accurate positioning.

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79

Injectors ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


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80

Injector Wiring 

Do’s and Don’ts – Do make sure wir es are properly routed – Do make sure clips are used  Clips are available in the Parts System – Do use the prop er Service Tool to torque Injector Connectors

Spring Clip Retainer


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81

High Pressure Pump ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


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82

Pump Solenoid Wiring

Service by pigtail


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83

Smart Wastegate Solenoid ECM Cam

Pump


Fuel Rail

6 EUI Injectors

Intake Air


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84

Wastegate Wiring Long fly lead used.  Clipped to air line around back of engine.  Route correctly to avoid ch afing. 


C6.6

85

ECM J1 ‘Customer’ Connection 

New Connecto r – Av ail able fr om Cat Parts System – New Removal Tool – Uses Standard Cri mp Tool


C6.6

86

OEM Connections 

Inputs – Power – Throttles – Switches



Outputs – Lamps – Relay



Datalink – J1939


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87

ECM Inputs - Power 

Ten Power Wires REQUIRED – 4 Plus B attery – 5 Minus Battery – 1 Ignition Switch

Beware of “ In” Harness Power & Ground Splices  Battery Minus sho uld go dir ectly to the Battery 

– Do Not Connect to Battery vi a the Chassis 

Use Correct Cable Size – Refer to A& I Guide for details.


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88

ECM Inputs - Throttles 

Two Types – An alo g  Requir e Validation Swit ch – PWM


Resistive track potentiometer type devices most common. ‘Hall’ effect type recommended, (non contact, longer life) Provide linear voltage output (Approx 0.5v to 4.5v) Should have a throttle movement detector, or Idle Validation Switch (IVS) on all applications for throttle failure detection.

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89

Throttle Position Sensor An alog  Pedal p ositi on/operator demand – 5 wires

As t he p edal is p ress ed



– Voltage incr eases fr om 0.5v to 4.5v Diagnostic Region 4.5v Voltage Output

0.5v

Diagnostic Region Low Idle

High Idle


Analogue Throttl e Posit io n Sensor. The analogue pedal sends a voltage signal to the ECM depending on the pedal position. This voltage, as shown above, varies from 0.5v to 4.5v. The ECM then interprets this signal into a required engine speed. A comparison between actual engine speed and desired engine speed is made and the amount of fuel being delivered to the engine is adjusted to increase or decrease the RPM of the engine.

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90

Throttle Position Sensor Pulse Widt h Modulated (PWM)  Three Wire – Power +8 Volts  From ECM – Ground  From ECM – Signal  To ECM 

No Validation Switc h Needed


PWM Throttle Positi on Sensor. Throttle incorporates conditioning electronics to provide Pulse Width Modulation (PWM) signal output. More consistent than a analogue throttle type. No need for Idle Validation Switch. Only three wire connection. Uses sensor 8v reference voltage. Less susceptible to voltage supply Variations. Less susceptible to outside noise/interference. The PWM pedal sends a signal to the ECM depending on the pedal position. This signal varies from 10% duty cycle to 90% duty cycle. The ECM then interprets this signal into a required engine speed. A comparison between actual engine speed and desired engine speed is made and the amount of fuel being delivered to the engine is adjusted to increase or decrease the RPM of the engine.

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91

Pulse Width Modulation 8v

ON

OFF

ON

OFF

Pulse Width Increasing

ON

OFF

Average voltage increasing

0v Time


PWM Sign al. At engine idle, duty cycle = 10 - 22%. Average time on (Pulse Width) = average voltage. Pulse runs at 500Hz. The position sensor generates a PWM signal which is a square wave. A square wave signal is either full voltage or no voltage − on or off. The percent of time the signal is on versus the time off is called the duty cycle. Duty cycle at low idle pedal position is 10% to 22%. Duty cycle at high idle pedal position is 75% to 90%. The pedal position sensor transmits the signal to the ECM at a constant frequency. This type of sensor provides a very accurate signal to the ECM with a smooth transition between acceleration and deceleration. The ECM determines if the sensor is faulty by monitoring the duty cycle. If the duty cycle is greater than 90% or less than 10%, the ECM will log an active fault.

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92

ECM Inputs - Switches 

9 Switch Inputs – PTO  On/Off  Set/Lower  Raise/Resume  Speed 1  Disengage – Mode  Mode 1  Mode 2 – Throttle  Thrott le Select – Shutdown Switch


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93

ECM Outputs - Lamps 

5 Lamps – 2 Recommended  Warning  Stop – 3 Optional  PTO Mode  Wait t o Start  Low Oil Pressure

+Battery

PTO Mode 61 61

ECM

STOP Lamp

60 60 J1 OEM

Connector

Warning Lamp 59 59 Wait to Start 63 63 Low Oil Pressure 62 62


ECM Output Numbers MIC Pin Numbers

C6.6

7 8 9 10 11 12 13 14 66 65 64 63 67 54 62 53

94

ECM Outputs - Relays 

OEM Installed – See A&I Guide for Relay Specifications



Driven by ECM – Part o f Cold Start Strategies

To glow plug relay

ECM J1 OEM Connector

40


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95

Grounding & Welding 

Grounding – Al ways ensur e th e gr ound st rap on th e ECM – Prevent EMI, Electro Magnetic Interference



Welding – Refer to A& I, OM&M or Troubl eshootin g Guide for details


Weldin g Precaution s. Turn off engine with Ignition Key. Disconnect negative terminal from battery, open battery isolation switch. If welding on the machine, ensure the welding earth clamp is placed close to the welding point. Protect wiring harness against welding debris and ‘splatter’ Electros tatic Paint Spraying Precaution s. Connect all 64 pins of the ECM directly to the spray booth ground. Connect the engine block to the ground at two points on bright metal. Jump Starting Precautio ns. Jump starting an can cause higher voltages, make sure they do not exceed the ECM maximum.

C6.6

96

Cylinder Block Grounding 

Engine Block m ust be properly ground ed – Provide a good return path for Starter Motor, Al ter nator , Star t A ids…

Ground Cables shou ld be mini mum, 67.4 mm² (00 AWG)  Starter Motor Stud, the first c hoice and directly back to battery  Tapped Holes on Engin e Block 

– Clean, Paint and dir t f ree – 10 mm zinc pl ated screw/washer – Tightened to 44 Nm – Conducti ve grease can be used May 2005 - Page 97 Caterpillar Confidential: Green

C6.6

97

Cylinder Block Grounding

1

2 Options for Ground Connection to Tapped Holes on Engine Bl ock

3


C6.6

98

Battery Battery Isolator Isolator Switches wit ches Installed Installed in loc ation, not normally accessible  Not to be used used for no rmal ‘Shutdown’ 

Diagnostic information – Looses Diagnostic

Disconnects battery durin g storage, transport and m aintenance aintenance  Improves Safety 

Av oi ds bat ter y d i schar sc har ge d ur i ng st or age – Av – Protects ECM duri ng welding

Aut A ut om ati c Iso l ato rs



– Must be controlled by a timer to allow normal ‘shutdown’ by the ‘Ignition’ switch Removi ng power from ECM Igniti on Switch Input  Removi May 2005 - Page 99 Caterpillar Confidential: Green

C6.6

99

Warning rnin g & Diagnosti c Lamps 

Strategy Change from 3054/6E Am ber Diag nost no st ic Lamp Lam p – Am os ti c Pr esent esen t  Ac ti ve Di agn osti – Red Warning Lamp Derate or Shutdow n  Derate



Light s Off : Everyth Everyth ing is OK


C6.6

100

Warning rni ng Lamp Strategy Warning Lamp

Shutdown Lamp Both On - Lamp Check Check for 2 Second Second at at key “ On”

Off

Off

Both OFF - No Faults Faults

On

Off

Warning Warning ON - Active Fault Fault

On

F

F

Of f

F

F

On

On

Warning Warning ON / Shutdown Shutdown Flashing Flashing - Engine Dera Derate te

Warning Warning Flashing Flashing / Shutdown OFF OFF - Warning Warning Warning Warning Flashing Flashing / Shutdown Flashing - Derate Derate Warning Warning ON / Shutdown Shutdown On - Shutdown


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101

Engi ne Warning and Protection Warn, Derate and Shutdow n thresholds  Read Only Screen 


Monitoring System. This screen provides all the warning, derate and shutdown levels that are currently set within the ECM. NOTE: These cannot be altered. The only way to change the values is to alter the actual flash file program.

C6.6

102

Electronic Diagnostics 

Electronic Techn ici an (ET) PC based Many fu ncti ons, reading of t emp, speed, pressures, switch positions, etc  For Installation work and full diagnostics  Configuration settings, Histograms, graphing, data log, etc  Programmin g the ECM,(Reflashin g, Configur ation)  Throttle Configuration, Analogue, PWM, MPTS, Variable Set Speed 


Diagnost ic Plug A diagnostic plug is available on the engine harness (certain engines may not have this facility). This allows connection of diagnostic service tool to either the Cat Data Link (CDL) or the CAN J1939 The Diagnostic connector fitted to the engine harness is a 9 pin Deutsch. The pin allocations are as follows are as follows: Pin

Description

A

Battery +

B

Battery -

C

CAN screen

D

PDL +

E

PDL -

F

CAN -

G

CAN +

H

Not connected

J

Not connected

C6.6

103

Diagnostic Fault Codes 

Two Types of Codes – Faults – Events



Faults – Problems w ith Components



Events – The Parameter being Measured is Out of range  E.g. Oil Pressure, Coolant Temperature


C6.6

104

Diagnostic Fault Codes 

4 Code Categories – Ac ti ve Di agnos ti c Codes  An y f ault that i s c ur rentl y o n t he engi ne.  Usually an electri cal probl em, connecti ons, etc – Logged Diagnostic Codes  Faults that have occur red and/or been repaired – Ac ti ve Ev ent s Co des  Currently Active Events – Logged Event Codes  An engine his to ry vi ew


C6.6

105

Understanding Diagnostic Codes

110

3

CID

FMI

Circuit/Component Identifier

Failure Mode Identifier

110 = Coolant Temperature Sensor

3 = Voltage High


FMI DESCRIPTIONS

C6.6

0

Data valid but above normal operating range

1

Data valid but below normal operating range

2

Data is erratic, intermittent or incorrect

3

Voltage above normal, or shorted to high source

4

Voltage below normal, or shorted to low source

5

Current below normal or open circuit

6

Current above normal or grounded circuit

7

Mechanical system not responding or out of adjustment

8

Abnormal frequency, pulse width or period

9

Abnormal update rate

10

Abnormal rate of change

11

Failure code not identifiable

12

Bad intelligent device or component

13

Out of calibration

14

Special instructions

15-31

Not available at present, for future use.

106

Active Diagnostic Fault Codes


Active Codes. This screen shows all the active diagnostic codes currently on the engine. i.e. any current faults with the engine. These faults will appear and as the faults occur. There is no need to clear the faults manually as there will automatically disappear when the problem is rectified.

C6.6

107

Logged Diagnostic Fault Codes


Logged Codes. This screen shows a history of all the faults that have occurred on the engine. They are logged with how many times the fault has happened, the first time it happened and the last time it happens. These are all in ECM hours.

C6.6

108

Logged Event Codes High Engine Coolant Temperature  High Intake Air Temperature  Low Engine Oil Pressure  Engine Over-speed  High System Suppl y Volt age (12/24Volt ) 

Faults That Could c ause Engine Damage


Event Codes f or J1939. Events are not supported in J1939 as used on the Electronic Service Tool (EST). Rather than an ‘E’ code, we are transmitting them using a Suspect Parameter Numbers (SPN) and a Failure Mode Identifier (FMI) Event Code (SPN)

FMI

Meaning

168

018

Low system voltage warning

172

016

High engine inlet air temp de-rate

190

0 or 16

Engine over-speed warning

110

016

High engine coolant temp warning

100

018

Low engine oil pressure warning

110

000

High engine coolant temp de-rate

172

016

High engine inlet air temp warning

100

018

Low oil pressure

These Fault codes can only be removed/cleared with an Electronic Service Tool.

C6.6

109

Active Event Codes


C6.6

110

Logged Event Codes


Logged Events. These codes are generated when the engine has gone into a warning, de-rate or shutdown. They are logged in the same way as the logged diagnostic codes.

C6.6

111

New Diagnostics 1- 2 Injector Data Incorr ect (CDL)  1 - 7 Injector Not Respond ing (CDL)  CID Can be 1 to 24 to Ident ify Cyli nder (CDL) 

651 - 2 Injecto r Data Inco rrect (J1939)  651 - 7 Injector Not Respo ndi ng (J1939)  CID 651 to 675 to Identi fy Cyl inder (J1939) 


C6.6

112

ET Diagnostic Test 

Diagnostic Test – Injector Solenoid Test  “ Click” Test – Override Parameters – Cylinder Cutout Test  Major Test for finding “ Good” or “ Bad” Injectors – Wiggle Test – Fuel Rail Pressure Test – Smart Wastegate Click Test – Injector Verificatio n Test


C6.6

113

Injector Installation 

Not Jus t a Mechanical Process – Physical installation – Electronic Installation  ET Required  E-Trim File Required


C6.6

114

Injector Removal 

Rocker Ar m – Loos en Set Screw – Slide Rocker to get access to Injector Hold Down Bolt


C6.6

115


Mechanic al Issues – Make Sure Copp er Washer is in Place – Make Sure the Old Washer is not still in the Injector Hole – Install Injector and Fuel Lines ‘finger tight’  Then tighten Injector Hold Down Bolt to the Proper Torque.


C6.6

116

Injector Insta nst allation 

Electron Electron ic Issues Issues – Re – Remember member to w rit e down Injector Serial Number and Confirmation Code BEFORE BEFORE you inst all the injector


C6.6

117

Injector Insta nst allation 

Installin g th e E-T E-Trim rim File – Finding – Finding E-Trim E-Trim File  On CD with the replacement Injector  On SIS Web



Connect Cat Cat ET – Se – Servic rvic e>Ca e>Calibr libr ations>Injector Tri m Calibr Calibr ations


C6.6

118

Injector Insta nst allation Select Select Injector t o be Programmed ‘Change’ butt on  Click on ‘Change’ 


C6.6

119

Injector Installation Find E-Trim File on you r Computer  Select it  Click on ‘Open’ butt on 


C6.6

120


ET inform s you t hat the file was successfully programmed into the ECM


C6.6

121

Injector Replacement 

If Injecto r is being r eplaced because of – “ Injector Data Incorrect” Or – “ Injector Not Responding” Diagnostics



Injector Verific ation Test mu st be run f rom Servi ce Tool


C6.6

122

Troubleshooting Injectors 

Using Inject or Swap Feature – Part o f th e Injector Calibr ation Screen – Swaps E-Trim Files for you – Click on ‘Exchange’ But ton – Use only as directed from Troubleshooting Guide


C6.6

123

C6.6 Quirks 

Fuel System Optimization Routine – Runs every hundred hours o r so – Au di bl e chang es when engin e is ru nn in g – NO perfor mance or Power Changes – Everything’s OK – Similar to HD ACERT engines


C6.6

124

Throttle Characteristics


Throttle Configuration Screen (EST). This screen capture shows where we can change the type of throttle and program its characteristics. Access to this screen is through the electronic service tool and will require a factory password to make changes to it.

Speed Demand (throttle) options, decided by customer. Highest one wins Manual switched throttle selection Throttle one Throttle two

C6.6

125

Idle Validation Switc h Operation 0%

10

20

30

Switch Closed (on)

40

50

60

70

80

90

100%

Switch Open (off)

Min Off Threshold

Max On Threshold


Why do we need an idle validation switch ? An ‘Idle Validation Switch’ provides an extra level of safety. It’s a ‘throttle movement’ detector. A micro switch is configured to operate when the pedal is in it’s released position. If the idle validation switch tells the ECM that the pedal is released, but the voltage signal tells the ECM that there is a speed demand, then the ECM can detect that there must be a fault with the throttle sensor or it’s wiring.

How is the idle validation switch applied A switch should be set up such that it closed (ON) when the pedal is released. It should open (OFF) when the pedal is depressed a little. Like other components, there will be some variation due to manufacturing tolerances and wear of switches and switch mountings. We define 2 thresholds in the software, “Max ON” and “Min OFF”.

Operating the throttle, forward Max On Threshol d ,

If the ECM reads a value above this and the switch is still ON (Closed) then it will register a fault Releasing the throttle, returning, Min Off Threshold If the ECM reads a value below this and the switch is still OFF (Open) then it will register a fault

C6.6

126

Idle Validation Switch 0%

10

20

Switch Closed (on)

Min Off Threshold 

30

40

50

60

70

80

90

100%

Switch Open (off) Max On Threshold

Betw een Min OFF and Max ON Thresh olds – When the ECM reads a raw sig nal hig her than Min OFF but l ower t han Max ON, it d oes not care what the switch posit ion is. This zone is to allow for tolerance of components.



Typical Idle Validation Swi tch (IVS) setti ngs


C6.6

127

Idle Validation Switch (IVS) 0%

10

20

Switch Closed (on)

Min Off Threshold

30

40

50

60

70

80

90

100%

Switch Open (off) Max On Threshold Machine Interface Connection 37

37

0 Volts Not Used

IVS

22

36

0 Volts 12 Volts


C6.6

128

Throttle Characteristics t i i m l g . i a D

i t s i m l s . p o

e o n d z e a D

Mechanical limits of pedal

Limits of potentiometer


Diagnostic Limits. In an analogue throttle, if a we try to measure values too close to the supply voltage (5V) or to ground (0V) then it is possible that short circuit, open circuits or ‘noise’ events will be mistaken for valid signals. In a PWM throttle, we cannot go as low as 0% or as high as 100% pulse width as both of these would be the same as no signal, or the full 8 volts. If the ECM measures values close to 0% or 100% raw signal then it is considered as an sensor fault and a diagnostic code is sent or logged. Example; 91-3, (Signal Voltage above normal or shorted to a higher voltage) Example; 774-4, (Signal Voltage below normal or shorted to a lower voltage) Position Limits. A throttle pedal is designed so that when it is in the released position it will give a voltage output of approximately 1 volt. The sensor (potentiometer) used has a tolerance of 1% of full travel. The manufacturing tolerances of the pedal add a further 2% (of full travel) tolerance. Pedals will be produced, therefore, which, when in the released position will give a voltage somewhere between 0.7 volts and 1.3 volt For this pedal the ECM would be configured to give an initial lower position of 15% (equivalent to 1.3V) and a lower position limit of 10% (equivalent to 0.7V) If a throttle pedal leaves the production line that gives an output of 1 volt, (when back). Then when the ignition is turned the ECM will see that this value is lower than the initial lower limit but greater than the lower position limit. It will now auto-calibrate to take 1volt to be the lower pedal position. Dead Zone. The lower Dead Zone will be a certain amount of throttle movement before the engine speed starts to rise. The Dead Zone is defined as a percentage of the raw signal. If the throttle auto calibrates then the Dead Zone will also move.

Upper Diagnostic Limit, Initial Upper Position, Upper Position Limit and Upper Deadzone are defined in exactly the same way as the lower ones

C6.6

129

Flashing the ECM 

Re-progr amming t he ECM will be required – ECM has been repl aced or – Flash File needs to be upd ated



Two Types of Fil es – Flash File  Base Engine Data 

Fueling/timing maps, cold start/governor strategies, set speed/mode switching, default values, etc

– Configuration File  Specific Custo mer Data 

e.g. Confi gurable parameters, idle speed,droop , etc


C6.6

130

Flashing the ECM 

Where do I get th e Data? – Extracted fr om Failed ECM – SIS Web  Flash File – TMI  Configuration  Being Moved to SIS Web


C6.6

131

Extracting Data from ECM 

Extracti ng t he Data fro m a Failed ECM – If Failed ECM can Communicate – Downloads AL L data to PC for u pload to n ew ECM



Servi ce>Copy Conf igu ration >Fleet Configuration


C6.6

132


Loadin g Data from a Failed ECM


C6.6

133


Saving Data to PC


C6.6

134


Retrieve Data from PC


C6.6

135


Program Data From PC


C6.6

136

Reprogramming (Flashing) an ECM


Flash Memory. To begin the Flash process first click on the Flash Memory icon.

C6.6

137

Factory Passwords 

C6.6/4.4 Requires fewer Factor y Password – Only  FLS/FTS  Interlock (Changing Flash File) – No Passwords Requir ed for:  Throttles  J1939 Communications (TSC 1)  Highest Enabled Rating


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Factory cto ry Password ssw ords s 

Passwor Passwor d Input Screen will automatically appear when trying a Factory Factory Password Protected Parameter Parameter change i s attempted


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Ad A d d i t i o n al Speed Sp eed Deman Dem and d Options Multi-Positi Multi-Positi on Throttl e Switch Switch - (MPT (MPTS) S) Up to 16 speeds  Power Take Off, PTO, (Variable (Variable Set Speed, Cruise Contro Contro l)  Torque Speed Control (TSC) via J1939 communication throttl e 


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Multi-P ult i-Posit osition ion Thrott le Swit Switch ch (MPTS)

46

MODE SWITCH 1

39

MODE SWITCH 2

MODE SWITCH 1 MODE SWITCH 2 10 POSITION ROTARY SWITCH

52

THROTTLE POSITION SWITCH 1

51


50


49



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Example of Multi-Position Throttle Switch operation Throttle Switch Input 4 Open Open Open Open Open Open Open Open Closed Closed

Throttle Switch Input 3 Open Open Open Open Closed Closed Closed Closed Open Open

Throttle Switch Input 2 Open Open Closed Closed Open Open Closed Closed Open Open

Throttle Switch Input 1 Open Closed Open Closed Open Closed Open Closed Open Closed

Throttle Switch Position 1 2 3 4 5 6 7 8 9 10

Valid Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Desired Engine Speed idle 1000 1200 1250 1400 1650 1670 2000 2100 2200


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Power Take Off (PTO)Variable Set Speed Control



Not Available if using t he Multi Positi on Switch (MPTS) option – Gives Vari able Set Speed/Power Take Off, Isochronous and droop control – Input Disable, provi ded for safety and prot ection systems – Provides simp le, Set Speed incr ease / decrease – Warning Lamp indication available – One Set Speed avail able – Pre-progr ammed speed


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Power Take Off (PTO)Variabl e Set Speed Contr ol

PWM THROTTLE SENSOR

ON / OFF

43

SENSOR SUPPLY8V

53

PWMTHROTTLESENSORINPUT

33

SENSORRETURN

52

PTOMODE- ON/ OFF

38

PTOMODE -SET/LOWER

51

PTOMODE- RAISE/RESUME

50

PTOMODE- SPEED1

49

PTOMODE- SPEED2

44

PTOMODE- DISENGAGE (NC)

SET / LOWER

RAISE / RESUME

SPEED 1 / SPEED2

nc no

DISENGAGE SWITCH


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Torque Speed Control (TSC1) 

Controlled Via the Controller Area Network (CAN) link: – Use J1939 message Torqu e Speed Cont rol 1 (TSC1) – This is a speed demand sign al, also know n as a communications ‘comms' throttle – CAN is the communication network between int elligent electron ic devic es ( several ECM’s) used on an machine application – Uses a version o f CAN that conform s to an int ernational standard kn own as SAE J1939

App li cati on con tro l, mo ni tor in g an d diagnosti cs is possi ble using SAE J1939




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Mode Selection A mo de d efi nes a fu el l im it map, a rated sp eed and a droop value for each throt tle input  This feature provi des the abilit y to s elect up to four di fferent modes of operation  A mo de d efi nes: 

– one of 2 rating s – a droop value for each thrott le input, 0 - 10% 

Mode selection i s cont rolled by 2 switched inputs


Mode Selection. Electronic control allows a signal mechanical specification to deliver different rating curves and droop characteristics. Each combinations of rating and droop is known as a mode. Each ECM may be configured to offer up to eight different operating modes. Torque/Fuel Limi t Maps. A maximum of four of four pre defined torque/fuel limit (Rating) curves may be selected when ordering the engine and these will be embedded into the ECM.These curves may in multi-mode operation, be toggled to provide different characteristics whilst the engine is running. Varying Droop. Speed droop is the rate at which an engine will increase in speed if the load is reduced for a given throttle setting. A drop slope of 10% would give a typical road driving feel. Some applications, however, require tighter governing with only small variations of speed against load. A droop of 2% may be suitable for a PTO mode, some applications may need isochronous governing where the droop is 0%. (variable set speed is Isochronous).

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Mode Selection Wiring

46

MODE SWITCH 1

39

MODE SWITCH 2

MODE SWITCH 1 MODE SWITCH 2 10 POSITION ROTARY SWITCH

52


51


50


49



Mode Selection. This feature provides the ability to select up to eight different modes of operation under operator control. A mode defines a fuel limit map, a rated speed and a droop value for each throttle input. Different modes of operation may be used to aid particular working environments by offering characteristics suitable for the work in hand. Examples would be an economy mode, a ploughing mode or a PTO mode. Up to three digital switch inputs may be used to determine which mode of operation is required. With three switches, a maximum of eight modes may be specified; with two switches, four modes; and with one switch, two modes. Each mode has a single defined fuel limit map, a rated speed and a individual droop values for throttle 1, throttle 2 and the comms throttle.

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Typical Mode Selection Examples

Mode Mode Mode Mode Selection Selection Selection Selection Switch Switch Switch Number Input 1 Input 2 Input 3 Open Open Open 0 Open Open Closed 1 Open Closed Open 2 Open Closed Closed 3 Closed Open Open 4 Closed Open Closed 5 Closed Closed Open 6 Closed Closed Closed 7

Valid

Rating Number

Yes Yes Yes Yes Yes Yes Yes Yes

1 1 2 2 3 3 4 4

Throttle 1 Throttle 2 Droop Droop Percentage Percentage 10 5 10 5 10 5 2 0

5 2 5 2 5 2 2 0

Comms Throttle Droop Percentage 0 0 0 0 0 0 0 0


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J1939 Datalink Adv ant ages :



– Uses less wi ring  Lower weight  Lower cost – Fewer connections  Increased Reliabilit y – Easier to install – Improved quality of s ignal – Can tr ansfer large amounts of Data


Types of messages. Commands (Torque Speed Control 1). Requests for data. Types of addressin g. Point to point. Broadcast.

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Example of J1939 Wiring Note. CAN wiring must be twisted

DCR Add ress 249

GEM

TSC1

Ad dre ss 23

Add res s 3

Nodes

Data Bus 120 Ohm ECM

DCR, Diagnostic Code Reader GEM, Generic Engine Monitor TSC, Torque Speed Control


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J1939 Datalink Example of J1939 CAN Commun ications  Transmis sio n ECM to engine ECM: 





‘Requests’ an engine speed change for a period of time while transmission changes gear.

Engine ECM to machi ne ECM: 

‘Br oadcasts’ engine parameters (eg engine speed, oil pressure, coolant temp)


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J1939 Datalink Fault Findin g Do make sure “ CAN high” and “ CAN low” are wired correctly  Do us e 120 terminating resistors  Do Make sure that no sho rt ci rcuit s are present  Do Check for possi ble electrical int erference 


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cat-c6_6-c4

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