Dokumen - Tips 3412 Generator Set 4bz00001 Upsebp2785 48 Documentation

6/11/2016 3412 Gener ator Set 4BZ00001- UP( SEBP2785 - 48) - Docum entati on
Previous Screen
Welcome: apache03
Product: GENERATOR SET
Model: 3412C GENERATOR SET 4BZ
Configuration: 3412 Generator Set 4BZ00001-UP
Systems Operation
3412 Generator Set Engines
Media Number -RENR1388-06 Publication Date -01/08/2015 Date Updated -26/08/2015

i02492531
Electronic Control System Components

SMCS - 1900
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/sisweb/… 1/15

Illustration 1 g01246160
Right side view
(1) Electronic Control Module (ECM)
(2) Coolant level sensor connector
(3) Rack position sensor
(4) Boost pressure sensor connector
(5) Engine coolant temperature sensor
(6) Engine oil pressure sensor
(7) Speed sensor
(8) Atmospheric pressure sensor

View A-A
(9) Fuel shutoff solenoid
(10) Rack solenoid (BTM)
(11) ATA data link
The electronic control system is designed into the engine's fuel system. The system is designed to electronically
control the delivery of fuel and injection timing.
The engine uses the following three types of electronic components:
Input component
Control component
Output component
An input component is one that sends an electrical signal to the ECM of the system. The signal that is sent varies
in either of the following ways:
Voltage
Frequency
The ECM interprets the signal from the input component as information about the condition, environment, or
operation of the engine.

A control component (ECM) receives the input signals from the input components. Electronic circuits inside the
control component evaluate the signals from the input components. These electronic circuits also supply
electrical energy to the output components of the system. The electrical energy that is supplied to the output
components is based on predetermined combinations of input signal values.
An output component is one that is operated by a control module. The output component receives electrical
energy from the control group. The output component uses that electrical energy in one of two ways. The output
component can use that electrical energy in order to perform work. As an example, a moving solenoid plunger
will perform work. The output component can use that electrical energy in order to provide information. As an
example, a dash panel light or an alarm will provide information to the operator of the engine.
These electronic components provide the ability to electronically control the engine operation. Engines with
electronic controls offer the following advantages:
Improvement in performance
Improvement in fuel consumption
Reduction in emissions levels
Various sensors feed engine data to the ECM. These sensors modify the following functions:
Boost pressure
Engine oil pressure
Engine speed
Fuel rack position
Throttle position
On/off ignition
The ECM processes the data. Then, the ECM sends electronic signals to the fuel injection solenoids. The fuel
injection solenoids move the fuel rack. This will optimize the efficiency and the performance of the engine.
The electronic engine control system also has the following built-in functions:
Engine overspeed
On board diagnostics
Data Link
A data link is used for the following items:
Communicate engine information.
Communicate with Caterpillar Electronic Technician Cat ET.
Calibrate the electronic engine control system.
Troubleshoot the electronic engine control system.

Program the electronic engine control system.
The electronic engine control system includes a Data Link. The Data Link communicates with other
microprocessor based devices. These devices are compatible with SAE Recommended Practices J1708 and
J1587. The Data Link can reduce the duplication of sensors by allowing the controls to share information.
The Data Link is used to communicate engine information to other electronic control systems. Also, the Data
Link can interface with Cat ET.
The Data Link monitors engine information. The engine information that is available on the Data Link includes
the following information:
Boost pressure
Engine identification
Engine speed
Oil pressure
Rack position
Status and diagnostic information
Throttle position
The Cat ET is used to program the customer specified parameters.
The Cat ET is one method of programming the customer specified parameters that are selected by the customer.
The tool plugs into the Data Link Connector. This allows the tool to communicate with the ECM. Also, the Cat
ET can be used to display the real time values of all the information available on the Data Link. This will help
diagnose engine problems.
System Diagnostic Codes

Table 1
Diagnostic Flash Codes
Flash Code Description of Code
21 Sensor Supply Voltage Fault
22 Rack Position Sensor Fault
24 Oil Pressure Sensor Fault
25 Boost Pressure Sensor Fault
26 Atmospheric Pressure Sensor Fault
27 Coolant Temperature Sensor Fault
32 Throttle Position Sensor Fault
33 Engine RPM Signal Fault

34 Loss Of Engine Speed Signal
35 Engine Overspeed Warning
42 Check Boost Sensor Calibration
43 Rack Subsystem Fault
45 Shutoff Solenoid Fault
46 Low Engine Oil Pressure Warning
48 Excessive Engine Power
51 Intermittent Battery Power to ECM
52 ECM or Personality Module Fault
53 ECM Fault
55 No Detected Faults
56 Check Customer or System Parameters
61 High Coolant Temperature Warning
62 Low Coolant Temperature Warning
Refer to Electronic Troubleshooting Guide for a complete explanation of the Diagnostic Codes.
Electronic Control Module (ECM) and Personality Module

ECM and personality module
(1) Electronic Control Module (ECM)
(2) Fuel outlet
(3) Fuel inlet
(4) Personality module
The 3412C generator set engine uses an ECM microprocessor. The ECM is mounted on the top of the
aftercooler housing. The ECM (1) and the personality module (4) are cooled by fuel. The fuel circulates through
a manifold between two circuit boards in the control module. The fuel enters the control module from the fuel
transfer pump. The fuel enters the control module through the fuel inlet (3). Then, the fuel exits the control
module through the fuel outlet (2) .
The inputs and the outputs to the control module are designed to withstand the short circuits to the battery
voltage without damage to the control. The electronic engine control system has the following features that are
designed into the system.
Resistance to radio frequency
Resistance to electromagnetic interference
The system has passed tests for interference that is caused by two-way radios and by switching noise.
The ECM power supply provides electrical power to all engine mounted sensors and actuators. The following
precautions have been designed into the ECM.

Reverse voltage polarity protection
Vessel power system voltage swings or surges due to sudden alternator load
In addition to acting as a power supply, the ECM also monitors all sensor inputs. The ECM provides the correct
outputs. Also, the ECM ensures the desired engine operation.
The ECM memory stores and identifies a selected factory engine rating. The memory also contains a personality
module identification code. This code is used to avoid unauthorized tampering or switching of personality
modules and other pertinent manufacturing information.
The wiring harness provides communications to the following areas:
Various sensors
Data link connector
Engine connectors
The personality module is attached to the ECM. The personality module provides all the instructions necessary
for the ECM to function. The personality module contains the engine performance information and the
certification information. This certification information includes fuel ratio information and rack control maps for
a particular ratings group that utilizes common engine components.
The ECM is programmed to perform the following functions:
Diagnostic tests on all inputs
Diagnostic tests on all outputs
Will separate a fault to a specific circuit
Once a fault is detected, the fault can be displayed on a diagnostic lamp. The diagnostic code can be read by
using Cat ET. A multimeter can be used to check most problems. Also, a multimeter can be used to troubleshoot
most problems. The ECM will either log or record most diagnostic codes that are generated during engine
operation. These logged or intermittent codes can be read by Cat ET.
Throttle Control Sensor

A throttle control sensor is used to interface with the throttle. The throttle control sensor output is a constant
frequency, pulse width modulation (PWM) signal rather than an analog voltage. Refer to pulse width modulation
in the glossary. The PWM signal overcomes the serious errors that can result from analog signals. These errors
occur from the following problems.
Leakage between pins
Contamination in the wiring harness
Contamination in the connectors
The engine returns to low idle if the PWM signal is invalid due to a broken or shorted wire.
Fuel Rack Controls

Cross section view of the rack housing
(1) Shutoff solenoid
(2) Rack solenoid (BTM)
(3) Fuel rack servo

Cross section view of rack position sensor
(4) Fuel rack
(5) Rack position sensor
(6) Shutoff override shaft and lever assembly (manual shutoff)
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/si sweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&call edpage=/sisweb… 10/15

Cross section view of engine speed sensor
(7) Flywheel starter gear
(8) Engine speed sensor
Engine oil pressure is used to move the fuel rack. An electronically actuated rack solenoid (BTM) (2) controls a
double acting hydraulic servo. The servo directs engine oil pressure to either side of a piston that is connected to
the fuel rack. The oil pressure moves the piston. The piston moves the fuel rack.
The servo group is a gerotor type oil pump. The servo group increases the pressure of the engine oil that is
supplied to the governor. The increased oil pressure allows a better regulation of engine speed during the rapid
application or the removal of heavy loads on the engine.
The rack solenoid (BTM) (2) is installed in the side of the rack actuator housing on the fuel injection pump. The
rack solenoid (BTM) (2) is controlled by the ECM. The lever of the rack solenoid (BTM) is engaged in a collar
on the rack servo valve. The rack solenoid (BTM) is spring loaded toward the fuel off position and must receive
a positive voltage in order to move in the fuel on position.
Rack position sensor (5) is located inside the rack actuator housing. The rack position sensor is attached to the
fuel rack by a magnet. The rack position sensor is a linear potentiometer that provides accurate feedback
information for the ECM.
In addition to the rack position data, the ECM receives data from other sensors that are located in the rack
actuator housing. The engine speed sensor (8) is triggered by radial slots on the flywheel. Oil pressure, inlet air
pressure, and the boost pressure sensors are mounted on the engine. These sensors are connected to the ECM.
The ECM will limit engine speed and power output of the engine if low oil pressure occurs. When there is a

change in boost and/or inlet air pressure, the control module adjusts the quantity of fuel or the timing of fuel that
is delivered to the engine.
The ECM operates an energized to run type shutoff solenoid (1). If the rack solenoid (BTM) (2) is unable to
move the fuel rack to the fuel off position, the shutoff solenoid will apply an addition force on the fuel rack to
move the rack to the fuel off position. A manual shutoff (6) (shutoff override shaft and lever assembly) is
provided. The manual shutoff control shaft is spring loaded to a neutral position.
If the shutoff solenoid fails to energize, the solenoid override may be used to move the shutoff lever away from
the fuel rack servo (3). This will allow the rack solenoid (BTM) to move the fuel rack even though the shutoff
solenoid is not energized.
The manual shutoff may be used to shut down the engine with the shutoff solenoid energized and power
maintained to the ECM. This method of shut down is used in some troubleshooting procedures.
The mechanical fuel ratio control, torque control group, and various adjustment screws have been eliminated.
The electronic control module performs all of these functions. The control module adjusts the engine power and
the torque rise. This compensates for the operation of the engine that either has plugged air cleaners or to limit
the amount of smoke.
The amount of fuel that is needed by the engine to maintain a desired rpm is determined by the ECM. With the
engine running at a desired speed, the engine speed will decrease when an additional load is applied. The signal
from the engine speed sensor (8) to the ECM changes. The control module performs the following tasks:
Receives the signal and other data
Processes all the data
Sends a positive voltage to the rack solenoid (BTM)
The rack solenoid (BTM) moves the valve in fuel rack servo (3). This will cause the fuel rack to move in the
Fuel On direction. The increase in fuel to the engine will increase engine speed. This action will continue until
the engine is again running at the desired speed or until the rack position has increased up to a rack position
limit.
With the engine running at a desired speed, the engine speed will increase when the load is decreased. The ECM
receives the changed signal from the engine speed sensor (8). The ECM reduces the electrical signal that goes to
the rack solenoid (BTM). The rack solenoid (BTM) moves the valve in the fuel rack servo (3). This will move
the fuel rack in the Fuel Off direction. The decrease in fuel to the engine will decrease engine speed. This action
will continue until the engine is again running at the desired speed.
The electronic engine control system allows the engine to be cranked and then allows the engine to start. The
throttle control is not needed. The ECM will automatically provide the engine with the correct amount of fuel
that is required to start the engine. Since some oil pressure is required for the fuel rack servo to move the fuel
rack, electronically controlled engines may require a slightly longer cranking time to start.
Governor Servo

Rack movement toward Full Fuel
(1) Piston
(2) Cylinder
(3) Sleeve
(4) Valve
(5) Fuel rack
(A) Oil inlet
(B) Oil outlet
(C) Oil passage
(D) Oil passage
When the rack solenoid (BTM) is energized, the rack solenoid (BTM) moves valve (4) to the left. The valve
opens oil outlet (B) and the valve closes oil passage (D). Pressure oil from oil inlet (A) pushes piston (1) and
fuel rack (5) to the left. Oil behind the piston goes through oil passage (C), along valve (4) and exits through oil
outlet (B).


No rack movement (const ant engine speed )
(1) Piston. (2) Cylinder. (3) Sleeve. (4) Valve. (5) Fuel rack. (A) Oil inlet. (B) Oil outlet. (C) Oil passage. (D) Oil passage.
(1) Piston
(2) Cylinder
(3) Sleeve
(4) Valve
(5) Fuel rack
(A) Oil inlet
(B) Oil outlet
(C) Oil passage
(D) Oil passage
When the desired engine speed is reached, the rack solenoid (BTM) holds valve (4) in a fixed position. Piston
(1) moves to the left until both oil outlet (B) and oil passage (D) are blocked by valve (4). Oil is trapped in the
chamber behind piston (1). This creates a hydraulic lock. The piston and the fuel rack movement is stopped.

Rack movement toward fuel off
(1) Piston
(2) Cylinder
(3) Sleeve
(4) Valve
(5) Fuel rack
(A) Oil inlet
(B) Oil outlet
(C) Oil passage
(D) Oil passage
When the rack solenoid (BTM) is de-energized, spring force in the solenoid moves valve (4) to the right. The
valve closes oil outlet (B) and opens oil passage (D). Pressure oil from oil inlet (A) is now on both sides of
piston (1). The area of the piston is greater on the left side than the area of the piston on the right side. The force
of the oil is also greater on the left side of the piston. The piston and the fuel rack (5) moves to the right.
Copyright 1993 - 2016 Caterpillar Inc. Sat Jun 11 2016 20:41:32 GMT+0200 (Egypt Standard Time)
All Rights Reserved.
apache03
Private Network For SIS Licensees.

Dokumen - Tips 3412 Generator Set 4bz00001 Upsebp2785 48 Documentation

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dokumen - Tips 3412 Generator Set 4bz00001 Upsebp2785 48 Documentation

Uploaded by

Copyright:

Available Formats

Electronic Control System Components

(1) Electronic Control Module (ECM)

(2) Coolant level sensor connector

(3) Rack position sensor

(4) Boost pressure sensor connector

(5) Engine coolant temperature sensor

(6) Engine oil pressure sensor

(7) Speed sensor

(8) Atmospheric pressure sensor

(9) Fuel shutoff solenoid

(10) Rack solenoid (BTM)

(11) ATA data link

The engine uses the following three types of electronic components:

Improvement in fuel consumption

Reduction in emissions levels

Engine oil pressure

Fuel rack position

Communicate engine information.

Communicate with Caterpillar Electronic Technician Cat ET.

Calibrate the electronic engine control system.

Troubleshoot the electronic engine control system.

Program the electronic engine control system.

Status and diagnostic information

The Cat ET is used to program the customer specified parameters.

System Diagnostic Codes

Flash Code Description of Code

21 Sensor Supply Voltage Fault

22 Rack Position Sensor Fault

24 Oil Pressure Sensor Fault

25 Boost Pressure Sensor Fault

26 Atmospheric Pressure Sensor Fault

27 Coolant Temperature Sensor Fault

32 Throttle Position Sensor Fault

33 Engine RPM Signal Fault

34 Loss Of Engine Speed Signal

35 Engine Overspeed Warning

42 Check Boost Sensor Calibration

43 Rack Subsystem Fault

45 Shutoff Solenoid Fault

46 Low Engine Oil Pressure Warning

48 Excessive Engine Power

51 Intermittent Battery Power to ECM

52 ECM or Personality Module Fault

56 Check Customer or System Parameters

61 High Coolant Temperature Warning

62 Low Coolant Temperature Warning

Electronic Control Module (ECM) and Personality Module

(1) Electronic Control Module (ECM)

(2) Fuel outlet

(3) Fuel inlet

(4) Personality module

Resistance to radio frequency

Resistance to electromagnetic interference

Reverse voltage polarity protection

The wiring harness provides communications to the following areas:

Data link connector

The ECM is programmed to perform the following functions:

Diagnostic tests on all inputs

Diagnostic tests on all outputs

Will separate a fault to a specific circuit

Throttle Control Sensor

Leakage between pins

Contamination in the wiring harness