CAT

CAT Engine D-3500B Control System

Prepared and Presented
By
Contents :

1. D-3500B Control System Features.

2. D-3500B Control System
System Benefits.
3. D-3500B Control System
System Components.
3.1. Sensors (Control System Input)
3.1.1. Pressure Sensor
Sensor..
3.1.2. Temperature Sensor
S ensor .
3.1.3. Throttle Position Sensor.
3.1.4. Speed Sensor
Sensor..
3.2. ECM (Control).
3.3. Output (Actuators).
 Contents
Contents (Continued):

4. Electronic Circuit Operation

4.1. Speed Timing Circuit 

4.2. Throttle Position Sensor Control Circuit.
4.3. Turbocharger Inlet Pressure Sensor Control Circuit.
4.4. Turbocharger outlet Pressure Sensor Control Circuit.
4.5. Engine Oil Pressure Sensor Control Circuit.
4.6. Coolant temperatur
temperature e Sensor Control
Control Circuit.
4.7. Fuel pressure Sensor Control Circuit.
4.8. Exhaust Temperature Sensor Control Circuit.
1. D-35
D-3500
00B
B Cont
Contr
rol System
stem Fea
Featu
tur
res
es::

1. Full
Full aut
authohoririty
ty of
of all
all Engin
Engine e func
functi tion
ons.
s.
2. Elec
Electr
tron
onicic Spe
Speeded Gov
Gover erni
ning
ng..
3. Cold
old Mod
Mode e St
Strategy
egy.
4. Alt
Altitu
itude Comp
Compen ensasati
tio
on.
5. Varia
ariabl
blee Inje
Injectctio
ion
n Timi
Timing
ng..
6. Engi
Engine
ne Mon
Monit itor
orin
ing g and
and prot
protececti
tion
on..
7. Opti
Optimi
mizizing
ng inj
injec
ecti
tion
on rat
rate.
e.
8. Optim
Optimiziizing
ng Inject
Injection
ion Pressu
Pressure re and Timing.
Timing.
9. Co
Cont
ntrrol Eng
Engin inee fuel
fuel to air
air rat
ratio
io..
10. Control Engine coolant
coolant temperature.
temperature.
11. Control
Control Engine
Engine fuelfuel pressure
pressure..
2. D-35
D-3500
00B
B Con
Contr
trol
ol System
stem Be
Bene
nefi
fits
ts::

1. Prec
Precis
ise
e Spee
Speedd Co
Contntrrol.
ol.
2. Fast
aster Co
Cold
ld star
starti
ting
ng..
3. Reduced
Reduced Engine
Engine Smoke
Smoke over
over the deferen
deferentt opera
operating
ting condition
conditions.
s.
4. Elec
Electr
tron
onic
ic Engi
Engine
ne prot
protec
ecti
tion
on
3. D-35
D-3500
00B
B Cont
Contr
rol System
stem Co
Comp
mpon
onen
ents
ts::

 D-3500B Engine Control System Consists of the following:

Control system

Input (Sensors) Control (Electronic Control Module) ECM Output (Actuators)

Pressure Speed Temperature Throttle

sensors sensors Sensors Position Sensor
3. D-350
D-3500B
0B Cont
Contro
roll Sys
Syste
tem
m Compo
Componen
nents
ts (Conti
(Continue
nued):
d):

Input (Sensors)
3. D-350
D-3500B
0B Cont
Contro
roll Sys
Syste
tem
m Compo
Componen
nents
ts (Conti
(Continue
nued):
d):

Control (ECM)
D-3500B Control System Components (Continued):

Output (Actuators)
3.1. Sensors (Control System Input):

 Introduction:

Sensors are Simple Electronic Devices that detect and Convert a change in
Pressure, Temperature or Electrical movement into an Electrical Signal

 Types of sensors:
1. Pressure.
2. Temperature.
3. Position.
4. Speed.
3.1.1. Pressure Sensor:

 Introduction

 Sense the changes in pressure and send

DC signals to ECM.
 ECM can detect the fault on the
pressure sensor:
 Supply Voltage = Signal Voltage
(Open Circuit)
 Signal Voltage = Zero (Short
Circuit)
3.1.1. Pressure Sensor (Continued):

 Pressure sensors used to sense:

1. Oil Pressure.

2. Fuel Pr
Pressure.

3. Turb
Turboc
ochar
harger
ger Inlet
Inlet Pres
Pressu
sure
re..

4. Turb
Turboc
ochar
harger
ger Outl
Outlet
et Pres
Pressu
sure
re..

5. Atmo
Atmosp
sphe
heri
ricc air
air Pres
Pressu
sure
re..

6. Crank
rankca
case
se Pr
Pressu
essure
re..
3.1.2. Temperature Sensor :

 Temperature Sensors are used to sense the changes of temperature and send a DC
current to the ECM
3.1.2. Temperature Sensor (Continued):
(Continu ed):
3.1.3. Throttle Position Sensor:

 Send a DC signal to the ECM with the Desired Which determined by the Operator.
3.1.4. Speed Sensor:

 Due to the change on the Magnetic field, the generated voltage

voltage changes, ECM
calibrated to detect Engine speed.
3.2. ECM (Control):

 Introduction:
The Engine Control Module ECM Is the Hart of the Electronic System.
System.
3.2. ECM (Continued):

ECM Provides the following features:

features:
3.3. Output (Actuators)

 Actuators Provides
Provides the following:
following:
1. Opti
Optimi
mize
ze inj
injec
ectition
on tim
timin
ing
g
2. Gove
Govern
rnin
ing
g fue
fuell Inj
Inject
ectio
ionn rate.
rate.
4. Electronic Circuit Operation
4.1. Speed Timing Circuit:
4.1. Speed Timing Circuit (Continued):

Speed Timing Circuit is the most important circuit in the engine, So the engine
will not run if failure done.

 Tells The ECM the position and speed of the Cam Shaft.

 ECM requires this signal to govern system operation.

4.2. Throttle Position Sensor Control Circuit:
4.2. Throttle Position Sensor Control Circuit (Continued):

Throttle Position Sensor Control Circuit operates as the following:

1. Operator
Operator select
select the desired
desired engine
engine speed
speed from the sensor
sensor.
2. The sensor
sensor send
send a signal
signal to the ECM with the desired
desired engine
engine speed
speed..
3. The ECM compare
compare between
between the actual
actual engine
engine speed
speed and the desired
desired..
4. Base
Ba sed
d on that
that ther
there
e are
are two
two case
cases:
s:
I. If the
the desir
desired
ed engine
engine speed
speed is less
less than
than the actual
actual,, ECM
ECM will
will incr
increas
ease
e the
the
duration of the actuators current consequently the amount of injected fuel
will increase.
II. If the desired
desired engine
engine speed
speed is greate
greaterr than
than the
the actual,
actual, ECM will decrease
decrease the
duration of the actuators current consequently the amount of injected fuel
will decrease.
decrease.
4.3. Turbocharger Inlet Pressure Sensor Control Circuit:
4.3. Turbocharger
Turbocharger inlet pressure
pressure sensor control
control circuit (Continued):

 This circuit is used to compare between the air pressure upstream and down stream the
air filter.
 If the pressure drop exceeds a certain value this means that the air filter is plugged, it
may cause engine heat and great engine damage.
 In this case ECM will turn on a lamp to indicate that it is significant to change the air
filter.
4.4. Turbocharger outlet Pressure Sensor Control Circuit:
4.4. Turbocharger outlet Pressure Sensor Control Circuit 
(Cont.):

 Measures
Measures the turbocharger out let pressure
pressure at the inlet manifold.
 Send this reading as DC signal to the ECM.
 The Engine ECM use this signal to optimize the fuel injection rate to prevent the
Engine black smoke.
 As a result the Turbocharger outlet Pressure Sensor Control Circuit control the
Fuel to Air ratio.
4.5. Engine Oil Pressure Sensor Control Circuit:
4.5. Engine
E ngine Oil Pressure Sensor Control Circuit (Continued):

 There are two Oil Pressure control sensors to measure the oil pressure After and
Before the lubrication oil filter.
 Sensors send the oil pressure reading as a DC signal to the ECM.
 If the Oil Pressure is less than a certain value, the engine will perform the
following:
  Warning.
 Derate.
 Shut down.
4.6. Coolant temperature Sensor Control
Control Circuit:
4.6. Coolant Temperature Sensor Control Circuit 
(Continued):

 The coolant temperature sensor is used to measure the engine coolant temperature
and send a DC signal to the ECM.
 There are three possibilities:
I. If the
the eng
engiine cool
coola
ant temp
temper
erat
atur
ure
e is
is less than a certain limit , The ECM will
operate the cold mode strategy which will advance the injection timing.
II. If the
the engi
engine
ne cool
coolan
antt temp
temper
eratu
ature
re is within a certain range,
range, The ECM will
operate
operate the engine ini n Normal Operation.
Operation.
III. If the
the engin
enginee coola
coolant
nt temp
temper
eratu
ature
re is Greater than a certain limit , The ECM
will perform the following:
 Warning.
 Derate.
 Shutdown.
4.7. Fuel pressure Sensor Control Circuit:
4.7. Fuel Pressure Sensor Control Circuit (Continued):

 There are two Fuel Pressure sensors to measure the Fuel pressure After and
Before the fuel oil filter.
 Sensors send the fuel pressure reading as a DC signal to the ECM.
 If the fuel Pressure is less than a certain value, The ECM will turn on a warning
Lamp on the operator compartment.
4.8. Exhaust Temperature Sensor Control Circuit:
4.8. Exhaust Temperature Sensor Control Circuit 
(Continued):

 There are an exhaust temperature sensor located on each exhaust manifold.

 Sensor send a DC signal to the ECM.
 ECM uses this signal to monitoring the excessive engine heat.
 If the exhaust temperature exceeds a certain limit, ECM will perform:
  Warning.
 Derate.
 Shut down.