3500B Fuel system familiarisation.

EUI injector operation and Trouble

shooting.

SERQ 4031 – ENG.ELECTRONICS

LERV 5149 – 3500B SERIES ENGINE
3500B Fuel system familiarisation.
EUI injector operation and Trouble
shooting.
INTRODUCTION TO 3500 B SERIES
Caterpillar 3508B Engine

• V- 8 Diesel
• 34.5 Liter (2105 Cu.in) Displacement
• Twin Turbocharged
• Ratings to 1500 Hp
Caterpillar 3512B Engine

• V- 12 Diesel
• 51.8 Liter (3158 Cu.in) Displacement
• Quad Turbocharged - Genset
• Ratings to 2250 Hp
Caterpillar 3516B Engine

• V- 16 Diesel
• 69 Liter (4211 Cu.in) Displacement
• Quad Turbocharged - Genset
• Ratings to 3500 Hp
Fuel systems overview:
 FIP and HP lines
 Mechanical Unit Injectors (MUI)
 Hydraulically Actuated Electronic Unit
Injector (HEUI)
Mechanically Actuated
Electronic Unit Injector (EUI)
Mechanically actuated
Electronically controlled
Unit
Injector
 Why
Why Electronic
Electronic Control?
Control?
 BLACK smoke - result of incomplete
combustion
 Charge shaping and injection pressure are
very significant
 Ability to change fuel injection timing
and duration very quickly is a must
 With Electronics we have decreased
noise, NOx, and particulates
Why
Why Electronic
Electronic Control?
Control?
 Electronics allow increased:
– horsepower
– fuel economy
– horsepower to weight ratio.
 Electronics allow decreased:
– Noise
– NOx
– Particulates
Why
Why Electronic
Electronic Control?
Control?

 To satisfy customers demand for:

– increased horsepower
– better fuel economy
– better reliability
– easier serviceability
 EUI Fuel system Overview

 Unit injector is positioned

above each cylinder
 An Electronic Control
Module (ECM) controls
fuel rate and timing
 Injectors are
mechanically actuated by
a camshaft
 EUI Fuel system Overview …
 Can inject fuel at up to
30,000 PSI
 High pressure fuel lines are
eliminated

 Limiting Factor:
– Injection pressure is
dependent on engine
speed (rpm)
Electronically
Electronically Controlled
Controlled
Engines CAN
Engines CAN.. .. ..
 Indicate active faults, logged faults, and
logged events
 Identify major component failure
 Identify sensor and actuator short or open
circuits
Electronically
Electronically Controlled
Controlled
Engines CANNOT
Engines CANNOT .. .. ..
 Troubleshoot themselves
 Identify marginal component
performance
 Identify inaccurate sensor readings
 Think for themselves
 EUI Fuel system Components:
 INPUT DEVICES - Sensors, switch
inputs, ground, power

 CONTROL DEVICES - Personality Module,

ECM, Data links

 OUTPUT DEVICES - Injectors, Actuators,

Warning lights,
guages
EUI Fuel system:
 System Components
 Component Introduction
 System Operation

 EUI fuel system

 Electronic Control System
 Diagnostics
EUI
EUI –– Injector
Injector Components
Components
Major
Major Components
Components of
of EUI
EUI
fuel
fuel system:
system:
EUI - Injectors
Actuators
ECM
Fuel Transfer Pump
Sensors
INJECTION
INJECTION COMPONENTS
COMPONENTS
EUI
EUI –– Injection
Injection Operation
Operation
EUI
EUI -- Injector
Injector Fill
Fill
 Without pressure from
the rocker arm, a
spring keeps the
plunger retracted.

 Fuel flows into the

injector through the
fill / spill port, past the
poppet valve and into
the barrel
EUI
EUI -- Mechanical
Mechanical Stroke
Stroke
 As the cam rotates,
it drives the plunger
downward

 Until the ECM

signals the start of
injection, fuel goes
out the
fill / spill port
EUI
EUI –– Injection
Injection
 On a signal from the
ECM(105 V), the
solenoid closes the
poppet valve

 Pressure elevates
at the tip to the
5,500 psi needed to
unseat the nozzle
check / tip

 Injection begins
EUI
EUI -- Injection
Injection
 Fuel continues to
inject until the ECM
signals the solenoid
to open the valve
 Injection timing and
duration is controlled
by the ECM
EUI
EUI -- Injection
Injection
 Fuel continues to
inject until the ECM
signals the solenoid
to open the valve
 Injection timing and
duration is controlled
by the ECM
EUI
EUI -- Injection
Injection
 Fuel continues to
inject until the ECM
signals the solenoid
to open the valve
 Injection timing and
duration is controlled
by the ECM
EUI OPERATION
 SFC CHART
300
223.3
250 197.2 196.4 199.9 209.7
196.8
200 251.4
sfc in gms/kwh(+/-3%)

196.7 197.9 203.3 215

150 196.5
100
50
0

%load
 Fuel Savings - 3500 B
series
Fuel savings -
compared to the
competetion 15 -20
% !!!
THE BEST in its class.
THE RESULT -
Customer laughs all
the way to the BANK.
ELECTRONIC CONTROL MODULE
 ECM :

• ECM is the computer that

controls the Engine.

• The Personality Module is

the software that controls
the computer.
 ECM :

• Neither ECM nor Personality

Module can “ Stand alone ”.

• The system process information from

operator and sensor inputs to precisely
optimize engine efficiencies through
interaction with the Electronic Unit
Injectors.
 ECM :

• “Control maps” are used to determine

fuel rate and timing by responding to
current conditions.
• Accurate diagnostic information is
available on a continuous basis.
 ECM :

•ECM real time monitors every ¼ Sec.

and does necessary correction.

• All system failures are automatically

reported to the operator.
 ECM :

• Timing varied with

respect to speed,
load and after cooler
temperature – 4D
timing map.
 ECM :

• Ensures that the

right amount of fuel
is injected at the
right time w.r.t. real
time monitored
parameters.
 ECM :

• Cold mode strategy

adjusts fuel injection
timing as a function
of jacket water temp,
engine speed &
injection duration.
ECM Construction Features:
 ECM Construction
Features:

• Fuel flow continually cools these

internal electronics, reducing variations
in temperature.

•Sealingproperties have been improved

over previous models.
ECM Construction
Features:

•Two 40-pin Deutsch connectors are

used for engine and OEM wiring
harnesses double the input/output
capacity.
•Each of the connectors is keyed for
error-free installation.
•23 to 27 – Volts DC power supply.
ECM Construction Features:

 Highlyintegrated PC
board design
 Dual 16 bit
microprocessors
 Flash memory
 Powerful self-
diagnostics
ECM is linked to…

• EUI s
• Sensors
• Battery
• Throttle
• Override Switch
• Engine over speed indicator
ECM used to
communicate to…

• Electronic Technician (ET)

• Electronic Control Analyzer

Programmer (ECAP)
 SENSORS
Monitors engine
performance
parameters and
supply information
to the ECM by
means of a Signal
voltage.
SENSORS
Sensors to ECM:
• Engine Speed and Timing Sensor
• Coolant Water Temperature sensor
• Fuel Temperature sensor
• Atmospheric Pressure sensor
• Throttle position sensor
• Filtered Oil pressure sensor
• Crankcase pressure sensor
• Turbo inlet pressure sensor
• Engine Boost pressure sensor
• Magnetic pickup sensor
Injector Solenoids - Schematic
ECM
A701-GY
Cyl. 1 16 sol.1 power
F726-YL
05 sol. 1/3 Return
J4 / P4
A703-BR 32 sole. 3 Power
Cyl. 3
F726-YL

J6 / P6 P2 J2
Injector Solenoids - Schematic
ENGINE SPEED
AND TIMING
SENSOR:

 The speed/timing sensor sends a pulse width

modulated signal to the ECM, providing
information for determining crankshaft position,
direction of rotation and the number of RPMs.
 ENGINE SPEED
AND TIMING
SENSOR:

Basic Functions:

1. Engine Speed measurement

2. Engine Timing measurement
3. Cylinder identification and TDC location.
 ENGINE SPEED
AND TIMING
SENSOR:

A unique tooth pattern on the camshaft timing

gear allows the ECM to determine camshaft
position and engine speed
 dowel
ENGINE SPEED
AND TIMING
SENSOR:

The dowel pin locates the wheel in the correct

position on the camshaft relative to the crank
shaft.
 ENGINE SPEED
AND TIMING
SENSOR:

Gear tooth pattern:

Total No.of teeth : 24 teeth

21 teeth - are large with small spaces

(80/20 relative size).
3 teeth - are equal dimension
(50/50 relative size).
 ENGINE SPEED
AND TIMING
SENSOR:

The Speed / Timing sensor has a separate

dedicated power supply.

ECM supplies 12.5 +/- 1 Volt to sensor.

ENGINE SPEED AND TIMING SENSOR:
ENGINE SPEED AND TIMING SENSOR:
ENGINE SPEED AND TIMING SENSOR:
ENGINE SPEED AND TIMING
SENSOR:

Connectors pin A & B transmit the common

power supply to the sensor.
The C connector pin transmits the signal from
the sensor to the ECM.
 ENGINE SPEED AND TIMING
SENSOR:

• 6V3093 Transducer Adapter

• 6V2197 Magnetic Transducer (probe)
• 7X1695 Cable (connects to P26)
 ENGINE SPEED AND TIMING
SENSOR:

A. Select "Service" from the main menu on the ET.

Select "Calibrations" from the drop-down menu.
Select Timing Calibration.

B. Press the "Continue" button on the ET. Wait until

the ET indicates that the ECM has calculated the
timing reference.
 ENGINE SPEED AND TIMING
SENSOR:

Note:
• Engine speed will be set to 800 rpm by the ECM
during the calibration.
• Magnetic probe should be 0.9mm (0.040”)
away from flywheel.
 ENGINE SPEED AND TIMING
SENSOR:

Note:
If the ET reads "CALIBRATION
UNSUCCESSFUL", the electronic injection timing
has not been set.
THROTTLE
POSITION
SENSOR:

• Provides continuous “desired speed”

information from the operator to the ECM.
THROTTLE
POSITION
SENSOR:

• The throttle position sensorgenerates a Pulse

Width Modulated signal (PWM) to communicate
this “desired engine speed” to the ECM.
PWM SIGNALS:

Duty Cycle = % of time ON

Vs
% of time OFF
PWM SIGNALS:

Pulse Width (Duty Cycle) varies with

throttle position.
PWM SIGNALS:

•Low idle 10% to 22%

•High idle 75% to 90%
Throttle Position Sensor

-B S D +B Droop
Adjust

1 2 3

24 25 26
Coolant Level
Sensor:

 Continuously monitors coolant level and

sends information to the ECM
 Heavy metal body for durability
 Straight thread o-ring mount for leak-free
engine
Coolant Level
Sensor:

• When the coolant level is normal, this wire

sends a +5 volt signal to the ECM.
• When coolant level drops below the tip of
the sensor, the wire sends a ‘0’ volt signal to
the ECM.
Temperature
Sensors:

Provides continuous
information to ECM

 Coolant temperature
 Intake air temperature
 Fuel temperature
 Oil temperature
 Exhaust temperature
 Coolant Temp.
Sensor:

Provides continuous
information to ECM

5 volt active sensor Very high coolant temp.

 High coolant temp. “Cold Mode”
Pressure Sensor:
• Pressure sensors
continuously Monitor
system pressure and
Send information to
ECM.
 Oil
 Atmospheric
 Boost
 Fuel
Oil Pressure Sensor:

• Oil Pressure
sensor measures the
oil pressure in the oil
gallery.

•Used for Low Lub.oil

pressure indication.
Boost Pressure
Sensor:

• Measures inlet
manifold pressure.

• Difference between • ECM uses this

inlet manifold and information to control
atmospheric Fuel rate.
pressure
measurement is
Boost Pressure.
Atmospheric Pressure
Sensor:

• Measures inlet
manifold pressure.

• Difference between • ECM uses this

inlet manifold and information to control
atmospheric Fuel rate.
pressure
measurement is
Boost Pressure.
Turbo Air inlet
Pressure sensor:

• Measures
turbocharger
compressor inlet
pressure.
• ECM uses this
information to control
Fuel rate.
Crankcase Pressure
Sensor:

• Measures
crankcase pressure.

• This sensor is used

to protect the engine
by giving advance
warning of damage
due to excessive
blow by.
Fuel Pressure
Sensor:

• Unfiltered fuel
sensor.
Fuel Pressure
Sensor:

• Filtered fuel
sensor.
Fuel Pressure
Sensor:

• Measures Filtered
and unfiltered fuel
pressure.

• The differential
pressure should be
Less than 15 psi.
Unit Injector Adjustment:

TOOLS NEEDED

9U5132 Timing Tool Group 1

6V3075 Dial Indicator 1
8S3675 Indicator Contact point(30mm) l
9U5137 Magnetic Fixture 1
9U5138 Setting Guage 1
9U5220 Timing Fixture Rod 1
9U6273 Rod sleeve Extension 1
 haran_k_p@cat.com
Mobile # 98450 29306

manoharan_r@cat.com
Mobile # 98455 42971