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Service Training: C7 and C9 Acert Technology Electronic Engine Controls
Service Training: C7 and C9 Acert Technology Electronic Engine Controls
April 2004
SERVICE TRAINING
TECHNICAL PRESENTATION
CONTENT
This presentation provides update information on the C7 and C9 ACERT On-highway Truck
Engines. This presentation may be used for self-paced and self-directed training.
OBJECTIVES
After learning the information in this presentation, the serviceman will be able to:
1. Locate and identify the new electronic components on the C7 and C9 ACERT Truck
Engines.
2. Explain the operation of the new components in the systems.
3. Explain new procedures in testing and adjusting.
4. Identify new tooling.
PREREQUISITES
3126B CD Cat HI300 Fuel System
C-9 CD Cat HI300B Fuel System
C-9 Engine - Systems and Controls
RENR1390-01
RENR1392
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REFERENCES
C7 and C9 On-highway Engines - Troubleshooting Guide
SENR9517
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TABLE OF CONTENTS
INTRODUCTION TO C7 AND C9 ACERT ELECTRONICS ...................................................5
SYSTEM CALIBRATIONS ........................................................................................................8
Injector Trim Calibration .......................................................................................................9
Downloading Injector Trim Files ........................................................................................10
Calibrating the Injectors ......................................................................................................18
SPEED TIMING SENSOR CALIBRATION ............................................................................26
C7 Timing Probe Installation ...............................................................................................27
C9 Timing Probe Installation ...............................................................................................29
SMART WASTEGATE .............................................................................................................30
C7 AND C9 ENGINE ECMS ...................................................................................................34
SUPPORT ...................................................................................................................................35
CONCLUSION ..........................................................................................................................36
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NOTES
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There are prerequisites for this presentation that should be completed in advance.
Prerequisite study references:
- 3126B CD ROM "HEUI HI300 Fuel System"
RENR1390-01
- C-9 CD ROM "HEUI HI300B Fuel System"
RENR1392
- C-9 Training Manual "C-9 Engine - Systems and Controls" (CD ROM)
SERH4050
The study reference CD ROMs offer a complete description of the existing 3126E and C-9
engine fuel systems. There are many similarities between the existing and the new engines.
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SYSTEM CALIBRATIONS
There are two calibration routines which will be covered in this presentation:
- Injector Trim Calibration
- Speed Timing Sensor Calibration
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On the SIS main menu, locate "Injector Trim Files" (arrow).
NOTE: If this item is not on the main menu, then the Dealer SIS Coordinator should be
contacted to have the SIS Web profile changed to turn on the "Injector Trim files."
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Follow the instructions on screen (left arrow) which says: "Please enter valid search criteria to
the right."
Follow the instructions on the right hand side, "Injector Trim File Download" which contains
the box for the serial number (right arrow).
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Enter the serial number in the box (arrow).
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Click on the Search button to download the file. The file will appear on the left hand side
(arrow).
Click on this file name to bring up the "File Download" dialog box.
The file version number can be ignored when performing the calibration.
There is no need to perform an upgrade if the injector file is an earlier version than the file in
SIS. This information is used by the factory and does not affect replacement or calibration of
injectors.
NOTE: Currently, only one file can be downloaded at a time.
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The File Download dialog box will appear:
- Check the radio button: Save the file to Disk
- Click the OK button
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Using the "Save As" dialog box:
- Click on the folder Injector Trim Files
- Click the Open button (opens the folder)
- Click the Save button in order to save the file to the PC
Once all the files are all downloaded to the PC, they can be uploaded to the Engine ECM for
calibration.
NOTE: A folder called "Injector Trim Files" can be created to contain the downloaded
trim files. Cat ET preferences can then be set to automatically look to this folder for the
trim files.
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Calibrating the Injectors
Open Cat ET and select the following from the Service pull down menu:
- Service / Calibrations / Injector Trim Calibration
NOTE: Both Dealer and Customer ET can be used to perform this operation. No
passwords are required to perform calibrations.
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Note the two buttons Change and Exchange at the bottom of the screen. Both of these
functions will be covered during the presentation.
Select the injector to program and click the Change button at the bottom of the screen. In this
case injector number one is selected. The "Open" dialog box will appear.
16
Select (highlight) the file for calibration to copy to the Engine ECM.
NOTE: The Cat ET preferences menu allows the Injector Trim Files folder to be
automatically located in the same way as the Flash File folder is located.
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Enter the Confirmation Code. This code was recorded from the injector with the serial number.
This code ensures that the correct and compatible file is selected a confirmation.
Cat ET determines if the Confirmation Code and the file are a valid pair. If not, Cat ET will
display an error message as shown on this slide.
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Upon successful completion, the Injector Serial Number field will have a new value.
NOTE: If the Serial Number field has not been programmed, an Active Fault will be
displayed. The engine will run, but with a warning light.
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There are times when two injectors may be exchanged for diagnostic purposes. In this case it is
necessary that the files are also moved to their respective injector positions.
To facilitate this operation and to reduce the risk of an error, a file exchange function has been
added to the Injector Trim File Calibration screen.
First, highlight the first injector to be exchanged as shown above; in this case number one.
Select the Exchange button.
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Upon successful completion, both Injector Serial Number fields will have new values.
It is recommended that a final check be made to ensure that the correct files are installed for the
respective injectors. Failure to match the files to the correct injectors may result in a customer
complaint of a roughly running engine.
NOTE: The Trim Files functions described in this section are only possible using
STW/Cat ET Version 2003B or higher. If a previous version is used, none of these
functions can be accessed.
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This illustration shows the C7 Timing Probe location on the block (arrow).
The probe location is behind the breather tube and below and left of the Engine ECM.
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SMART WASTEGATE
This illustration shows the wastegate canister (right arrow) and the bleed orifice (left arrow)
which is in the air line tee.
The "smart wastegate" is similar to a mechanical wastegate.
This control system is installed primarily for emissions reasons. The smart wastegate is
electronically controlled by the Engine ECM using a solenoid valve and is operated
mechanically using boost for actuation.
The Smart Wastegate Control also modulates boost pressure to prevent cylinder overpressure
and turbo overspeed at high engine speed and load while still providing enough cylinder
cooling at peak torque.
This control also enhances high altitude performance by maintaining boost as the vehicle gains
altitude.
Boost pressure is modified by bypassing a portion of the engine exhaust around the
turbocharger. The amount of exhaust bypass is determined by the position of the wastegate
canister linkage. The wastegate canister position is dependent on the pressure to the canister.
This pressure is controlled by the wastegate solenoid.
NOTE: The system also works just like the October 2002 "bridge" engine Smart
Wastegate Control. Bridge engines had improved emissions over the previous
production engines, but were not able to fully meet the all of the EPA standards.
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The wastegate solenoid is controlled by the Engine ECM and is used to modulate the wastegate
position and therefore manifold pressure.
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The wastegate solenoid is actually a modified hydraulic valve. The solenoid operation is
similar to the HEUI hydraulic pump control valve.
A PWM signal from the Engine ECM controls the modulation of the wastegate bypass valve.
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With the Smart Wastegate Control, boost comes from the intake manifold and passes through
the wastegate solenoid control valve.
The wastegate solenoid is mounted on the inlet manifold. There is a bleed orifice which allows
the system to bleed pressure from the wastegate line.
The Engine ECM reads engine speed, load, and actual boost. The Engine ECM compares these
parameters to the desired boost maps and closes the loop to drive actual pressure to meet the
desired pressure.
When the solenoid is de-energized, boost is allowed to enter the wastegate canister and limit
pressure. As the Engine ECM sends current to the solenoid, pressure is blocked from the
manifold and is allowed to bleed from the canister through the orifice.
Currently all C9 engines are equipped with the Smart Wastegate Control.
Only the high horsepower C7 engines have the Smart Wastegate Control (above
186 KW/250 HP).
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SUPPORT
For support, technicians are available at the Caterpillar On-Highway Engine Call Center
24-hours a day, seven days a week to answer technical questions. Upon calling the 800 number
shown on the slide, a voice menu will direct the caller to the appropriate contact to handle a
situation.
This phone number should be used for technical assistance with C7 and C9 engines.
The e-mail address for the call center is shown above.
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CONCLUSION
ACERT takes us to the next generation of diesel engines without the necessity of EGR and
other maintenance intensive accessories.
In brief, ACERT could be described as sophisticated simplicity. The problems of meeting the
emissions standards are met with sophisticated, intelligent software and cutting edge injectors
using the latest technology. This technology does not result in additional sophistication in
maintenance and repair.
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Turbocharger speed
Manifold pressure
Cylinder pressure
Emissions
High altitude engine performance enhancement
All of the above
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Turbocharger speed
Manifold pressure
Cylinder pressure
Emissions
High altitude engine performance enhancement
All of the above