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CM20160713 53120 03004 PDF
CM20160713 53120 03004 PDF
DIESEL ENGINE
CONTROL SYSTEMS
Contents
©2008 Caterpillar®
All rights reserved.
Application and Installation Guide Diesel Engine Control Systems
SECTION CONTENTS
Engine Protection & Monitoring Electronic Modular Control
System Parameters.............. 2 Panels (EMCP 3) ................ 21
• Lubrication System • EMCP II
• Cooling System • EMCP 3.x
• Fuel System • Alarm Modules
• Air Starting • Customer Interface Module
• Combustion Air (CIM)
• Miscellaneous Customer Supplied Shutoffs 25
• Off-Engine Parameters
Engine Communication
Engine Control, Protection and
Methods ........................... 25
Monitoring Systems for
• Customer Communication
Electronic Unit Injection (EUI)
Module
Engines.............................. 9
• ECM and Control Software • Programmable Relay Control
Module
• Electronic Unit Injection
(EUI) • Relay Driver Module
• Engine Instrument Panel • PL 1000 Series
(EIP) Communication Modules
• ADEMTM II Wiring Methods &
Considerations................... 29
• ADEM A3
• Wire Size & Type
• ADEM A4
• Wire Insulation
Engine Control, Protection and
• Support & Protection of
Monitoring Systems for
Harnesses
Mechanical Unit Injection (MUI)
Engines.............................17 • Connectors
• 3600 Series Engines • Routing Considerations
• 3500 Series & Smaller MUI Reference Material ............. 30
Engines • Media Numbers
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Diesel Engine Control Systems Application and Installation Guide
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Application and Installation Guide Diesel Engine Control Systems
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Diesel Engine Control Systems Application and Installation Guide
external oil sumps in addition to the inlet regulator can be detected with
engine lubricating oil pan (dry sump a gradual rise in water temperature.
configuration). In those instances Aftercooler Water Pressure
the lubricating oil pressure measured Aftercooler water pressure loss
at the scavenge pump outlet can will result in high inlet manifold air
detect lubricating oil system temperature and lubricating oil
problems prior to low pressure temperature, which can quickly
detection in the main engine cause engine damage. An electric
lubricating oil supply. emergency aftercooler water pump
Engine Cooling System can be installed to automatically
start upon loss of engine driven
Jacket Water Temperature pump pressure; this is sometimes
Jacket water temperature increase required by marine classification
is almost as serious as loss of societies. A low aftercooler water
lubricating oil pressure but is more pressure alarm can warn of
likely to occur. Similar reduction of impending problems with an engine
engine speed and load, or stopping mounted aftercooler water pump.
the engine can minimize engine
damage. Set the high coolant Expansion Tank Level Alarm
temperature contactors to activate While coolant temperatures and
within 2.8°C (5°F) of the highest pressures are important indicators
normal engine temperature at the of cooling system operation, an
time of installation. expansion tank level alarm can
indicate low coolant level or loss of
Jacket Water Pressure system coolant. A low coolant level
It is important to maintain jacket can activate an alarm or shutdown
water pressure to the engine to to prevent engine overheating.
prevent overheating. Single engine In a variable speed application,
applications can use an electric observance of expansion tank level
emergency jacket water pump to reduction proportional to engine
automatically start upon loss of speed increase is an indicator of
engine driven pump pressure; this is air trapped in the coolant system
sometimes required by marine piping.
classification societies. A low jacket
water pressure alarm can warn of Cooling Water Loss-of-Flow Alarm
impending problems with an engine Warning of coolant loss can allow
mounted jacket water pump. the operator to save an engine
which would otherwise be lost to
Aftercooler Water Temperature overheat failure. If the high water
It is also beneficial to monitor temperature sensors discussed
aftercooler water temperature to below are not immersed in water
help determine operating efficiencies they will not activate. This coolant
of the coolers in the aftercooler detection switch is installed on 3600
circuit. Impending problems with the series engines at the highest location
in the jacket water system.
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Application and Installation Guide Diesel Engine Control Systems
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Application and Installation Guide Diesel Engine Control Systems
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Diesel Engine Control Systems Application and Installation Guide
Start/Stop Control
Electronic Unit Injection (EUI)
The ECM contains the logic and
The ECM controls the timing,
outputs for control of engine starting
duration and pressure of the fuel by
and shutdown, including
varying the signals to the injectors.
prelubrication and postlubrication,
The timing and duration of the
when available. The customer
injection is controlled through the
programmable logic responds to
injector solenoid valves, common to
signals from the engine control
all electronic unit injectors. The fuel
switch, emergency stop switch,
pressure is controlled by two
remote start switch, data link and
different means of injector actuation,
other inputs, and the ECM controls
either mechanical or hydraulic.
the prelube pump (when available),
the starting motor, and the Mechanically Actuated Electronic
electronic fuel injector solenoid Unit Injectors (MEUI)
valves at the appropriate times. Mechanically Actuated Electronic
Unit Injectors (MEUI) use the engine
Engine Speed Governing
camshaft and push rods to generate
The ECM governs the engine speed
fuel injection pressure, while the
by controlling the amount of fuel
ECM controls the amount of fuel
that is delivered by the injectors.
injected.
The ECM compares the desired
engine speed to the actual engine Hydraulically Actuated Electronic
speed and adjusts the amount of Unit Injectors (HEUI)
fuel injected until the actual engine Hydraulically Actuated Electronic
speed matches the desired engine Unit Injectors (HEUI) use a hydraulic
speed. Desired speed is based on pump and engine oil to generate fuel
throttle switch position and actual injection pressure. On the HEUI
speed is based on engine system, the ECM modulates the
speed/timing sensor signals. injection pressure by varying the
signal to the Injection Actuation
Engine Monitoring and Protection Pressure Control Valve (IAPCV). The
The ECM monitors engine IAPCV controls the pressure of the
operation and the electronic system. high-pressure oil which pressurizes
Any problems with the engine the fuel that is in the injectors.
operation will cause the ECM to
generate an event code that can
issue a warning or cause a
shutdown. The severity of the
condition determines whether a
warning is issued or the engine is
shutdown. Problems with the
electronic system produce a
diagnostic code that can be
addressed using the Cat ET.
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Application and Installation Guide Diesel Engine Control Systems
Figure 1
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Diesel Engine Control Systems Application and Installation Guide
Figure 2
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Application and Installation Guide Diesel Engine Control Systems
Figure 3
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Diesel Engine Control Systems Application and Installation Guide
Table 2
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Application and Installation Guide Diesel Engine Control Systems
Figure 4
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Diesel Engine Control Systems Application and Installation Guide
away of the metal at the contact Metal conduit will help reduce
points of the connector, also called electrical noise, therefore, it's
pin fretting. Corrosion and pin preferred to plastic conduit.
fretting may cause intermittent or Avoid coiling extra wire length as
complete failure of the connector. it can create an electromagnetic
compatibility (EMC) issue. Extra wire
Routing Considerations
length should be cut off.
Wiring for DC circuits, magnetic
pickups, thermocouples and RTD's Ground loops should be avoided.
can be routed in common conduits. Ground points should not be painted.
However, they must not be in the Electrical codes and service
same conduit with AC circuits. In publications or instructions may
addition, AC circuits greater than provide additional requirements.
600 volts should be separated from IEEE Standard 142 (Recommended
AC circuits less than 600 volts. Practice for Grounding of Industrial
Route harnesses and wires away and Commercial Power Systems),
from hot exhaust manifolds and IEEE Standard 1100 (Recommended
turbochargers, unless special Practice for Powering and Grounding
insulation is provided. Route so Sensitive Electronic Equipment) may
wiring is protected from abrasive also provide additional assistance.
wear (such as grommets). Avoid To avoid potential noise, signal
sharp harness radii to reduce wiring should not exceed 30 m
unnecessary wire connection strain. (98 ft) in length.
Route harnesses such that someone Installations with severe
standing on equipment does not electromagnetic interference (EMI)
strain wiring. may require shielded wire run in
conduit, double shielded wire, or
other precautions.
Reference Material
REHS1187: Electronic Installation
Media List
Guide for 3126B, C7, C9, C12,
The following information is
C15, C18, and C32 Marine
provided as an additional reference
Engines
to subjects discussed in this manual.
EERP1000: Caterpillar
Communications Toolkit
LEBE5255: EMCP 3 Application &
Installation Guide
©2008 Caterpillar®
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LEBW4981-01 ©2008 Caterpillar Printed in U.S.A.
All rights reserved.