Slide 1

Training Centre

1100D with ACERT® Technology

Advanced Combustion Emission Reduction Technology

 Slide 2
Training Centre

Important

 The product training information is

distributed for informational purposes
only. It is not to be construed as
creating or becoming part of Perkins
contractual or warranty obligations
 The appropriate service literature,
should always be the final authority
and source of information
 Slide 3
Training Centre

1100D Benefits
Installed Package
Engine Size
Cooling Pack

Cost of Ownership
Fuel Economy
Service Period

Environment
Emission compliant
Filtration

Electronic Functionality
Machine Integration

Refinement
3 dBA Noise Reduction
Quality of Noise
Low Vibration

Ratings
Power
Torque

Product Functionality
Cold Start
Fuel Compatibility
PTO
 Slide 4
Training Centre

Electronically assisted…..

 To create…
 Lower emissions

 Better fuel consumption

 Versatile control
 Slide 5
Training Centre

Tier 3 Dates and Ratings

January 2008 January 2007 January 2006

Emissions Emissions Emissions

260 – 330HP*
1106D
120 – 250HP

1104D 68 – 140HP

100HP 175HP
*Application Specific
 Slide 6
Training Centre

Features

4 Valve Head
ECM

Timing

Cylinder
Crankshaft Block
Fuel
System
 Slide 7
Training Centre

Engine Cylinder Block

New Block for 6 cyl
Scalloped & Ribbed
Noise reduction
Parent Bore
Oversized Piston Service
Solution

6.6 Litres
Same Bore/Stroke as 1104C
105mm/127mm
 Slide 8
Training Centre

Piston Design
 Pistons
 Two Types
 Gallery Cooled
 Non - Gallery Cooled
 Aluminium
 Quiescent Bowl Design
 New Ring Pack
 Improved Oil Control
 Graded Rods for Piston
Protrusion
 Square Boss to the
Front
 Slide 9
Training Centre

6cyl. Connecting Rod

 Connecting Rods Dimple
 Fracture Split
 Removal from the
Top
 Notches
 Bearing Alignment
 Not Interchangeable
Top to Bottom
 3 Lengths for Piston
Protrusion
 Always use New Bolts
 Dimples for Orientation
Dimple Notch
 Slide 10
Training Centre

6 cyl. Crankshaft
 Crankshaft
 Balanced Steel Forging
 Induction Hardened
 Larger Mains Diameter
 84mm, 8mm Increase
 Larger Rod Diameter
 72mm, 9mm Increase
 15mm Bearing Overlap
Increase
 Withstands Higher
Torsional loads
 Lead free Bearings
 100% Front PTO
 Slide 11
Training Centre

6 Cyl. Thrust Bearing

 Crank Thrust Bearing
 #5 Main

 Fitted into the Block

 Faces the Crank

 Squared ends for

proper installation
 Aluminium Base -
Lead Free
 Slide 12
Training Centre

Isolated Sump
 Sump connected to block via isolator plate.
 Gives benefits of noise reduction.

Isolator plate
 Slide 13
Training Centre

Main Bearing Caps

 Bearing Caps
 Installation

 Use Torque and

Angle Method
 Details in D&A
Manual
 Slide 14
Training Centre

Cylinder Head Details

 4 Valve per Cylinder
 Centered Injector
 Non-Sleeved Injector Bores
 Service -
 Non-Serviceable Valve
Guides and Seats
 Head face can be
machined once
 0.006”
 Adapter required for
current Valve Spring
Compressor
 Slide 15
Training Centre

Head Bolt Torque Sequence

11 7 3
10 14
6
2
4
12 8
13
9
5

1
 Slide 16
Training Centre

Head
 Head
 Multi-Layered-Steel
(MLS) Head Gasket
 Fourteen - 16mm
bolts
 Single Use

 Torque and Angle

Tightening Method
 Slide 17
Training Centre

Rocker Assembly
 Bridge can be installed Inlet (Long)
either way
 Single Bolt per Rocker
Lever
 Lash settings the same
for Inlet and Exhaust
 Injectors can be
replaced without
removing Rockers

Exhaust (Short)
 Slide 18
Training Centre

6 cyl. Oil Pump

 Serviced as Assembly
 Left Hand filter to Right
Hand filter requires
additional piping

Pressure
Relief Valve
 Slide 19
Training Centre

Timing Case
Camshaft locating Idler Hub Location
 Timing Case pin boss

 Increased Clearance
for Idler Hub access
 PTFE Crank Seal
with dust seal
 New Seal
Recommended if
Timing Case is
removed
 Use “dummy” Sleeve
when front Pulley is Front oil seal, please
ensure seal to crank alignment
Removed
 Slide 20
Training Centre

Timing Case
 Timing Case Alignment
Tool must be used
 Allows Idler Gear
and Hub to be
installed as an
assembly

Cam Gear
Alignment
 Slide 21
Training Centre

Idler Gears
 Two Types
 Bronze

 Double Needle

 Dependant on PTO
requirements.
 Slide 22
Training Centre

Camshaft Thrust Washer

 Two Different Camshaft
Thrust Washers
 One Notch

 PTO mounted RHS

 Greater than
35Nm Torque Notches
 Two Notches

 All others

Two Notch Version

 Slide 23
Training Centre

Static Timing
 Pinning the Crank to
No.1 TDC
 Notch in Crank

 Remember to
Remove Pin

 TDC access point

 Service Tool
Available
 Slide 24
Training Centre

Camshaft Timing
 Camshaft Alignment Tool
 Not a Tight Fit

 Ease of Assembly
 Slide 25
Training Centre

Crank Speed/Timing
 New Sensor
 Located at Rear of Block
 Reads tooth wheel
attached to the Crank
 Slide 26
Training Centre

Innovative fuel system

 Caterpillar Fuel System using common rail
technology
 Low Pressure
 300kPa (43 PSI)
 20 Micron Primary Filter
 2 Micron Secondary Filter
 Fuel Cooler Required on some arrangements

 High Pressure
 Up to 160 MPa (1600bar - 23,200 PSI)
 Fluid penetration safety hazard.
 Hardened Fuel Lines
 External Fuel Manifold
 Slide 27
Training Centre

Clean fuel system

How small is a micron?

 Slide 28
Training Centre

Fuel System Handling

IMPORTANT!!
 Cap all fuel passages Immediately after removal
 Do Not “Blow Out” or “Wash Out” any fuel passages
 Place removed parts in clean area
 Do Not pre-fill filters
 Remove packaging and protective caps immediately
before installation
 Fuel Lines cannot be reused
 Slide 29
Training Centre

Fuel System Schematic

 Slide 30
Training Centre

High pressure system

Injectors

High pressure
fuel rail

High pressure fuel

pump
 Slide 31
Training Centre

High Pressure Fuel Pump

 Two Pumps
 High Pressure

 Transfer

 HP Pump Lubricated by
Engine Oil
 Longer Life

 Lube Oil Feed

 Pump Speed/Position
Sensor
 Transfer Pump
 Slide 32
Training Centre

High PressureFuelFuel
Leak offPump
to Tank

Fuel in to HP
Fuel leak off to Pump
tank
To secondary
filter

Fuel out to HP
manifold
From Primary
Filter

Pump Speed/Timing Sensor

 Slide 33
Training Centre

Pump facts…
 Stroke in phase injection
 Self Bleeding
 Do not Crack lines to bleed

 Lock pump before removal

 Replace HP Fuel line when Pump is removed
Two Cams – 2 or 3 lobes each
Solenoid adjusts rail pressure
and return to tank
Needs to be Timed
Lock
in Place BEFORE
Removal
 Slide 34
Training Centre

Fuel Pump Function

 Pump Raises Pressure
 ECM tells Injector to Fire
 Rail Pressure Drops
 ECM Detects Pressure Drop
 Sensed by Fuel Rail
Pressure Sensor
 ECM tells Pump Solenoid to
Increase Volume
 Also tells Pump Solenoid
to Spill fuel once
pressure is reached
 Do it Again!
 Slide 35
Training Centre

Transfer Pump
 Driven by High
Pressure Pump
 Draws Fuel through
Primary Filter
 Output Pressure
 300 to 400 Kpa
 43 to 58 PSI
 Transfer Pump Primed
by Priming Pump
 Hand or Electric
 No Lift Pump
Required
 Slide 36
Training Centre

High Pressure Fuel Rail

 Do’s & Don’ts Fuel Injector
 Do Check for leaks Manifold Lines
 Do Not Loosen HP
Connection with Engine
Running
 Do Replace HP Pipes
After they are Loosened
 Do Replace ALL HP Pipes
if new manifold is
Installed
 Do Not Force Pipes to
Fit
 Do Cap Manifold and
Injector Connections
Immediately when HP Feed From High Pressure Pump
Pipe is removed
 Slide 37
Training Centre

High Pressure Fuel System

Fuel Injector
 Do’s & Don’ts Manifold Lines
 Do Remove HP Cap
just before
installation
 Do Keep your Work
Area Clean
 Do Think about
Cleanliness when
working on HP
System
 Do Make Sure all
Clips and Clamps are Feed From High Pressure Pump
tight and in position
 Slide 38
Training Centre

Fuel Pressure Relief Valve

High Pressure Relief
Valve

 Protects System from

Over-Pressure
 Opens at Constant
Pressure of 160 MPa
(23,000 PSI)
 Withstands Spikes to
190 Mpa (27,500 PSI)
 Returns fuel to Tank
 Slide 39
Training Centre

Fuel Return from Head

Fuel leak off pipe

 Excess Fuel Returned Fuel
to Transfer Pump Return
from
 Low Pressure
Head
 Slide 40
Training Centre

Injector Function Stage 1

 ECM Energizes Injector
 Valve Lifts Solenoid
energized
 Fuel Flows to Nozzle

Valve

To nozzle
 Slide 41
Training Centre

Injector Function Stage 2

Solenoid de-
 Injector De-energizes energized
 Valve Closes
 Unused fuel flows back
to Transfer Pump via
passage in the Head
 Slide 42
Training Centre

Fuel Injector Connections

Two connection types

Electrical

High pressure
fuel
 Slide 43
Training Centre

Fuel Injector
 Do’s and Don’ts
 Do Use Proper Torque on
Electrical Connection
 Service Tool Available
 Do Finger Tighten all
Clamps and HP Lines, First,
then torque properly
 Do Cap the Injector
Immediately After
Removing HP Fuel Line
 Do Make Sure the O-Ring
and Copper Washer are in
place
 Do Not Re-use O-Ring or
Cooper Washer
 Slide 44
Training Centre

Fuel Injector
 Do’s and Don’ts
 Do Write down the
Injector Serial Number

and Confirmation Code

before you install the
Injector
 Do use EST to Program
ECM with proper
Injector Trim File
 Do Look for the Trim
File CD in the Injector
Box
 Slide 45
Training Centre

Cleanliness
 Thoroughly clean equipment before disassembling

 Use only NEW protective caps to seal fuel

connections

 Replace HP Fuel Lines if they have be loosened

 Slide 46
Training Centre

Fuel Injection Serviceability

 NEVER loosen high pressure pipes when engine is
running! 23,000 PSI

 Use Electronic Service Tool to Troubleshoot Injector

Problems

 Injectors have no serviceable parts.

 Warranty will only be paid with evidence of the
correct tests.

 Pump Solenoid is non serviceable.

 If the solenoid is removed the whole pump
assembly must be replaced.
 Slide 47
Training Centre

Fuel Injection Serviceability

 Transfer pump is a serviceable item, separate

from High Pressure pump.

 Fuel Pump Speed sensor is serviceable.

 Slide 48
Training Centre

Smart Wastegate
Smart Wastegate Controller
 Can be found on All
Variable Speed Engines
 Controls Wastegate
Actuator
 Optimizes Engine
Performance
 Driven by PWM Signal
from the ECM
 Service as an Assembly
 12 or 24 volt
 Slide 49
Training Centre

Wastegate Actuator

 The Wastegate arm is

set at 1 mm travel

 Refer to Service Manual

for Adjustment
Procedure
 Slide 50
Training Centre

Smart Wastegate Schematic

Intake Manifold Pressure IN

The ECM tells the Solenoid
(Boost)
what quantity of Pressure
to pass

Looks at:
 Desired Speed
 Load Measures Intake
 Boost Manifold pressure
 Slide 51
Training Centre

Glow plugs
 Now installed on ALL
Engines!
 Much Improved
 Sheathed Element
 Can Achieve 850 °C in 4
Seconds!!
 Controlled by ECM
 Via OEM Relay

1 - Early Glow plug

2 - Improved version.
 Slide 52
Training Centre

Electronic Components

Intake Air Intake Manifold

Temperature Pressure Sensor
Sensor
Coolant Fuel Rail Pressure
Temperature Sensor
Sensor

ECM

High
Pressure
Crank
Fuel Pump
Speed/Position
Sensor

Pump/Cam Oil Pressure

Speed/Position Sensor
Sensor
 Slide 53
Training Centre

Engine Wiring Harness

 Both Connectors and
Harness are serviceable
 Pump Connector
Serviced by Pigtail
 Slide 54
Training Centre

Engine Wiring Harness

 Harness Do’s and Don’ts
 Do clip the harness

 Do Not Force Connectors

 Keyed to ensure Correct Connection

 Do Not use “Electrical Grease”

 Do make sure seals are in good condition

 Slide 55
Training Centre

On Engine Components

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 56
Training Centre

ECM

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 57
Training Centre

A4-E2 Fuel Cooled (ECM)

4mm Allen Key

Fuel Flow ‘in’

J1 ‘Customer’
Connector Anti-Vibration
Mounts

J2 ‘Engine’
Connector

Fuel Flow ‘out’

Ground Strap
 Slide 58
Training Centre

A4-E2 Electronic Control Module (ECM)

 ECM Controls:
 Fuel Pressure

 Speed Governing

 Air/Fuel Ratio

 Start/Stop Sequence

 Engine Protection
Devices/ Diagnostics
 Slide 59
Training Centre

A4-E2 ECM Voltages/Current

 Nominal battery supply voltage 9-32 volts

 Expected voltage range/current draw…

 12V system / 9-16 volts / Max 30 Amps

(8mA ‘Sleep’)
 24V system / 18-32 volts / Max 15 Amps
(10mA ‘Sleep’)
 Slide 60
Training Centre

A4-E2 ECM

 Do Use the proper tools to tighten the ECM

Connector Screws
 6 Nm (4.4 lb-ft)

 Do Use the ‘Test ECM’ Feature when

troubleshooting the ECM
 Slide 61
Training Centre

Temperature Sensors

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 62
Training Centre

Temperature Sensors
 Thermistor sensing
devices
 Resistance varies
with temperature
 As temperature
increases its
resistance decreases
 Passive Sensor
 Does not need it’s
own power supply
 Slide 63
Training Centre

Temperature Sensors

Negative Temperature Coefficient (NTC)

2,500
(Resistance)
Ohms

1000

20 C Increasing Temperature
 Slide 64
Training Centre

Temperature Sensors
Thermistor

Ground
Pin No 2

Signal
Pin No 1
 Slide 65
Training Centre

Temperature Sensors
 Engine Coolant Temperature Sensor
 Used for engine protection,
Warning/Derate/Shutdown
 Intake Manifold Air Temperature Sensor
 Used for engine protection, Warning/Derate

 Smoke limiting

 Both Used for

 Cold Start Strategy

 Data Link Information

 Slide 66
Training Centre

Diagnostic Example

110-3 Signal shorted to a high voltage or Open Circuit

4.8
Very cold Temp

Warning Temp
VOLTS

Start Derate Temp

Shutdown
Temp

0.2
110-4 Signal shorted to a lower voltage

Temperature
 Slide 67
Training Centre

Pressure Sensors

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 68
Training Centre

Pressure Sensors

Intake Manifold
Pressure Sensor

Oil Pressure Sensor

Fuel Rail Pressure Sensor

 Slide 69
Training Centre

Fuel Rail Pressure Sensors

 Fuel Rail Pressure Sensor
 Determines Fuel Rail Pressure
 Continuous Operating Pressure
200 Mpa
 Maximum without damage,
260 Mpa
(burst at 320 Mpa)
 Temperature Range, -40º to
+160ºC
 Sensor has M12 x 1.5 Thread
 Requires Special ‘Crush’
Washer for Sealing
 Ensure there is no Rail
Pressure before removal
 Serviced as a Kit with ‘Crush’
Washer
 Slide 70
Training Centre

Intake Pressure Sensor

 Intake Manifold Air
Pressure Sensor
 Measures Manifold Air
Pressure
 Used to calculate
air/fuel ratio
 Used for smoke
limiting strategy
 Measures atmospheric
pressure on “key-on”
 Serviced as a Kit with
O-ring
 Slide 71
Training Centre

Oil Pressure Sensors

 Engine Oil Pressure
Sensor
 Used for engine
protection,
Warning/Shutdown
 Provides signal for
pressure gauge, via
the ECM
 Serviced as a Kit
with O-Ring
 Slide 72
Training Centre

Pressure Sensors
 Integrated circuit
 Capacitive sensor
 Voltage output
varies with pressure
 Sensor conditions the
signal voltage output to
the ECM
 Active Sensor (Needs
it’s own power supply)
 Slide 73
Training Centre

Speed\Timing Sensors

ECM
Cam Pump

Intake Air
Crank
Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 74
Training Centre

Crank Speed/Timing
 New Sensor
 Located at Rear of Block
 Reads tooth wheel
attached to the Crank
 Slide 75
Training Centre

Speed/Timing Sensors
 Two speed/position sensors
 Crankshaft - Primary

 High Pressure Fuel Pump - Secondary

 Two Wire ‘Hall Effect’

 Produce Conditioned Square Wave

 Engine will Run if the Primary sensor fails

 ‘Limp Home Mode’ - 1200 rpm Max

 Engine will Not Shutdown if Secondary sensor Fails

 Cannot be re-started if the engine is stopped.
 Slide 76
Training Centre

Crank Speed/Timing
 59 Teeth + 1 Wide
tooth
 6º Between teeth

 Wide tooth “tells” ECM

Crank Position
 Ring fitted on rear of
crank with Teeth
pointing to Nose end
 Use proper thread lock
adhesive when re-using
screws

Dowel Hole
 Slide 77
Training Centre

HP Pump Speed/Timing Sensor

Speed / Timing Speed / Timing

Sensor Sensor ‘Target’
36 Teeth
 Slide 78
Training Centre

Hall Effect Sensor

 Produces a conditioned square-wave signal
Old

New

Signal Output Waveform Crank Speed/Position Target

 Slide 79
Training Centre

Injectors

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 80
Training Centre

Injector Wiring
 Do’s and Don’ts
 Do make sure wires
are properly routed
 Do make sure clips
are used
 Clips are available
in the Parts
System
 Do use the proper
Service Tool to
torque Injector
Connectors
 Spring Clip Retainer
 Slide 81
Training Centre

High Pressure Pump

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil
Smart Wastegate
Solenoid Fuel Rail
Diagnostic 6 EUI Injectors
Connector Intake Air
 Slide 82
Training Centre

Pump Solenoid Wiring

 Service by pigtail
 Slide 83
Training Centre

Smart Wastegate Solenoid

ECM
Cam Pump

Intake Air
Crank

Coolant
Oil

Smart Wastegate Fuel Rail

Solenoid 6 EUI Injectors
Diagnostic
Intake Air
Connector
 Slide 84
Training Centre

Wastegate Wiring
 Long fly lead used.
 Clipped to air line
around back of engine.
 Route correctly to
avoid chafing.
 Slide 85
Training Centre

ECM J1 ‘Customer’ Connection

 New Connector
 Available from
Perkins Parts
System
 New Removal Tool

 Uses Standard
Crimp Tool
 Slide 86
Training Centre

OEM Connections
 Inputs
 Power

 Throttles

 Switches

 Outputs
 Lamps

 Relay

 Datalink
 J1939
 Slide 87
Training Centre

ECM Inputs - Power

 Ten Power Wires REQUIRED
 4 Plus Battery

 5 Minus Battery

 1 Ignition Switch

 Beware of “In” Harness Power & Ground Splices

 Battery Minus should go directly to the Battery
 Do Not Connect to Battery via the Chassis

 Use Correct Cable Size

 Refer to A&I Guide for details.
 Slide 88
Training Centre

ECM Inputs - Throttles

 Two Types
 Analogue

 Require Validation
Switch
 PWM
 Slide 89
Training Centre

Throttle Position Sensor

Analogue

 Pedal position/operator
demand Diagnostic Region
4.5v
 5 wires
Voltage
 As the pedal is pressed Output

 Voltage increases
from 0.5v to 4.5v 0.5v
Diagnostic Region
Low High
Idle Idle
 Slide 90
Training Centre

Throttle Position Sensor

Pulse Width Modulated (PWM)

 Three Wire
 Power +8 Volts

 From ECM

 Ground

 From ECM

 Signal

 To ECM

 No Validation Switch
Needed
 Slide 91
Training Centre

Pulse Width Modulation

ON OFF ON OFF ON OFF

8v

Pulse Width
Increasing
Average
voltage
increasing

0v

Time
 Slide 92
Training Centre

ECM Inputs - Switches

 9 Switch Inputs
 PTO
 On/Off
 Set/Lower
 Raise/Resume
 Speed 1
 Disengage
 Mode
 Mode 1
 Mode 2
 Throttle
 Throttle Select
 Shutdown Switch
 Slide 93
Training Centre

ECM Outputs - Lamps

 5 Lamps +Battery
 2 Recommended PTO Mode
61
61
 Warning
STOP Lamp ECM
 Stop 60
60
J1 OEM
 3 Optional Connector
Warning Lamp
59
59
 PTO Mode

 Wait to Start Wait to Start 63

63

 Low Oil
Low Oil Pressure
Pressure 62
62
 Slide 94
Training Centre

ECM Outputs - Relays

 OEM Installed
 See A&I Guide for Relay
Specifications
ECM
 Driven by ECM J1 OEM
 Part of Cold Start Connector
Strategies

To glow plug relay 40

 Slide 95
Training Centre

Grounding & Welding

 Grounding
 Always ensure the ground strap

on the ECM
 Prevent EMI, Electro Magnetic
Interference

 Welding
 May damage the ECM!
 Refer to A&I, OM&M or Troubleshooting
Guide for details
 Slide 96
Training Centre

Cylinder Block Grounding

 Engine Block must be properly grounded
 Provide a good return path for Starter Motor,
Alternator, Start Aids…
 Ground Cables should be minimum, 67.4 mm² (00
AWG)
 Starter Motor Stud, the first choice and directly back
to battery
 Tapped Holes on Engine Block
 Clean, Paint and dirt free
 10 mm zinc plated screw/washer
 Tightened to 44 Nm
 Conductive grease can be used
 Slide 97
Training Centre

Cylinder Block Grounding

1 2

Options for Ground Connection to

3
Tapped Holes on Engine Block
 Slide 98
Training Centre

Battery Isolator Switches

 Installed in location, not normally accessible
 Not to be used for normal ‘Shutdown’
 Looses Diagnostic information
 Disconnects battery during storage, transport and
maintenance
 Improves Safety
 Avoids battery discharge during storage
 Protects ECM during welding
 Automatic Isolators
 Must be controlled by a timer to allow normal
‘shutdown’ by the ‘Ignition’ switch
 Removing power from ECM Ignition Switch Input
 Slide 99
Training Centre

Warning & Diagnostic Lamps

 Strategy Change from 1100C
 Amber Diagnostic Lamp

 Active Diagnostic Present

 Red Warning Lamp

 Derate or Shutdown

 Lights Off : Everything is OK

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Warning Lamp Strategy

Warning Shutdown
Lamp Lamp
Both On - Lamp Check for 2 Second at key “On”
Off Off Both OFF - No Faults

On Off Warning ON - Active Fault

On F Warning ON / Shutdown Flashing - Engine Derate

F Off Warning Flashing / Shutdown OFF - Warning

F F Warning Flashing / Shutdown Flashing - Derate

On On Warning ON / Shutdown On - Shutdown

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Engine Warning and Protection

 Warn, Derate and Shutdown thresholds
 Read Only Screen
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Electronic Diagnostics
 Three types of Diagnostic Service Tools
 Electronic Service Tool (EST) PC based

 Many functions, reading of temp, speed,

pressures, switch positions, etc
 For Installation work and full diagnostics

 Configuration settings, Histograms, graphing,

data log, etc
 Programming the ECM,(Reflashing,
Configuration)
 Throttle Configuration, Analogue, PWM, MPTS,
Power Take Off (PTO) Speed
 Slide 103
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Electronic Diagnostics
 The two other types types of Diagnostic tools
 Generic Engine Monitor (GEM)

 Instant SAE J1939 fault code availability

 Multi functional analogue/digital display

 Different Languages.

 SAE J1939 Diagnostic Code Reader

 Reads J1939 Codes only.
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Diagnostic Fault Codes

 Two Types of Codes
 Faults
 Events
 Faults
 Problems with Components/cables
 Events
 The Parameter being Measured is Out of
range – Could cause engine damage
 E.g. Low Oil Pressure, High Coolant
Temperature.
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Diagnostic Fault Codes

 4 Code Categories
 Active Diagnostic Codes

 Any fault that is currently on the engine.

 Usually an electrical problem, connections, etc

 Logged Diagnostic Codes

 Faults that have occurred and/or been repaired

 Active Events Codes

 Currently Active Events

 Logged Event Codes

 An engine history view

 Slide 106
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Understanding Diagnostic Codes

110 3

CID FMI
Circuit/Component Failure Mode
Identifier Identifier

110 = Coolant Temperature Sensor 3 = Voltage High

 Slide 107
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Active Diagnostic Fault Codes

 Slide 108
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Logged Diagnostic Fault Codes

 Slide 109
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Logged Event Codes

Faults That Could cause Engine Damage

 High Engine Coolant Temperature

 High Intake Air Temperature
 Low Engine Oil Pressure
 Engine Over-speed
 High System Supply Voltage (12/24Volt)
 Slide 110
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Active Event Codes

 Slide 111
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Logged Event Codes

 Slide 112
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New Diagnostics
 1- 2 Injector Data Incorrect (PDL)
 1 - 7 Injector Not Responding (PDL)
 CID Can be 1 to 24 to Identify Cylinder
(PDL)

 651 - 2 Injector Data Incorrect (J1939)

 651 - 7 Injector Not Responding (J1939)
 CID 651 to 675 to Identify Cylinder (J1939)
 Slide 113
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ET Diagnostic Test
 Diagnostic Test
 Injector Solenoid Test
 “Click” Test
 Override Parameters
 Cylinder Cut-out Test
 Major Test for
finding “Good” or
“Bad” Injectors
 Wiggle Test
 Fuel Rail Pressure Test
 Smart Wastegate Click
Test
 Injector Verification
Test
 Slide 114
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Injector Installation
 Not Just a Mechanical Process
 Physical installation

 Electronic Installation

 EST Required

 E-Trim File Required

 Slide 115
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Injector Removal
 Rocker Arm
 Loosen Set Screw

 Slide Rocker to get access to Injector Hold

Down Bolt
 Slide 116
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Injector Installation
 Mechanical Issues
 Make Sure Copper Washer is in Place

 Make Sure the Old Washer is not still in the

Injector Hole
 Install Injector and Fuel Lines ‘finger tight’

 Then tighten Injector Hold Down Bolt to

the Proper Torque.
 Slide 117
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Injector Installation
 Electronic Issues
 Remember to write
down Injector Serial
Number
and
Confirmation Code
BEFORE you install
the injector
 Slide 118
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Injector Installation
 Installing the E-Trim File
 Finding E-Trim File

 On CD with the replacement Injector

 Will be available on PTMI

 Connect EST
 Service>Calibrations>Injector Trim
Calibrations
 Slide 119
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Injector Installation
 Select Injector to be Programmed
 Click on ‘Change’ button
 Slide 120
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Injector Installation
 Find E-Trim File on
your Computer
 Select it
 Click on ‘Open’ button
 Slide 121
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Injector Installation
 ET informs you that the
file was successfully
programmed into the
ECM
 Slide 122
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Injector Replacement
 If Injector is being replaced because of
 “Injector Data Incorrect”

Or
 “Injector Not Responding” Diagnostics

 Injector Verification Test must be run from

Service Tool
 Slide 123
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Troubleshooting Injectors
 Using Injector Swap Feature
 Part of the Injector Calibration Screen

 Swaps E-Trim Files for you

 Click on ‘Exchange’ Button

 Use only as directed from Troubleshooting Guide

 Slide 124
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Quirks
 Fuel System Optimization Routine
 Runs every hundred hours or so

 Audible changes when engine is running

 NO performance or Power Changes

 Everything’s OK

 Similar to HD ACERT engines

 Slide 125
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Throttle Characteristics
 Slide 126
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Idle Validation Switch Operation

0% 10 20 30 40 50 60 70 80 90 100%

Switch Closed
(on)
Switch Open (off)

Min Off Max On

Threshold Threshold
 Slide 127
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Idle Validation Switch

0% 10 20 30 40 50 60 70 80 90 100%

Switch Closed
(on)
Switch Open (off)

Min Off Max On

Threshold Threshold

 Between Min OFF and Max ON Thresholds

 When the ECM reads a raw signal higher than Min OFF but
lower than Max ON, it does not
care what the switch position is.
This zone is to allow for tolerance of components.
 Typical Idle Validation Switch (IVS) settings
 Slide 128
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Idle Validation Switch (IVS)

0% 10 20 30 40 50 60 70 80 90 100%

Switch Closed
(on)
Switch Open (off)

Min Off Max On

Threshold Threshold

Machine Interface Connection

0 Volts

Not Used
0 Volts
IVS 12 Volts
 Slide 129
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Throttle Characteristics

it
im
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ag
Di
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zo
ad
its De
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s.
po

Mechanical limits of pedal

Mechanical limits of pedal

Limits of potentiometer
Limits of potentiometer
 Slide 130
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Flashing the ECM

 Re-programming the ECM will be required if:
 The ECM has been replaced

or
 Flash Files need to be updated
 Two Types of Files
 Flash File
 Base Engine Data
 Fueling/timing maps, cold start/governor
strategies, set speed/mode switching, default
values, etc
 Configuration File
 Specific Customer Data

eg Configurable parameters, idle speed,droop, etc

 Slide 131
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Flashing the ECM

 Where do I get the Data?

 Configuration -Extracted
from failed ECM (if you
can Communicate)
 PTMI
 Flash File

 Configuration
 Slide 132
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Extracting Data from ECM

 We can Extract the
Data from a Failed ECM
 If Failed ECM can
still Communicate
 It will download ALL
data to PC for
upload to new ECM
 Service>Copy
Configuration>Fleet
Configuration/ECM
Replacement.
 Slide 133
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Extracting Data from ECM

 Loading Data from a Failed ECM
 Slide 134
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Extracting Data from ECM

 Saving Data to PC
 Slide 135
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Extracting Data from ECM

 Retrieve Data from PC
 Slide 136
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Extracting Data from ECM

 Program Data From PC
 Slide 137
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Reprogramming (Flashing) an
ECM
 Slide 138
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Factory Passwords
 1100D Requires fewer Factory Passwords
 Only

 FLS/FTS

 Interlocks (Changing Flash File)

 Now no Passwords are needed for:

 Throttles

 J1939 Communications (TSC 1)

 Highest Enabled Rating

 Slide 139
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Factory Passwords

 Password Input Screen.

 This will automatically
appear when trying to
change a parameter
protected by a ‘Factory
Password’
 Slide 140
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Additional Speed Demand

Options
 Multi-Position Throttle Switch - (MPTS) Up
to 16 speeds
 Power Take Off, PTO, (Variable Set Speed,
Cruise Control)
 Torque Speed Control (TSC) via J1939
communication throttle
 Slide 141
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Multi-Position Throttle Switch

(MPTS)
 Slide 142
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Example of Multi-Position Throttle Switch operation

 Slide 143
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Power Take Off (PTO)Variable

Set Speed Control
 Not Available if using the Multi Position Switch
(MPTS) option
 Gives Variable Set Speed/Power Take Off,
Isochronous and droop control
 Input Disable, provided for safety and protection
systems
 Provides simple, Set Speed increase / decrease

 Warning Lamp indication available

 One or Two? Set Speeds available

 Pre-programmed speed
 Slide 144
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Power Take Off (PTO)Variable

Set Speed Control
 Slide 145
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Torque Speed Control (TSC1)

 Controlled Via the Controller Area Network (CAN)
link:
 Use J1939 message Torque Speed Control 1
(TSC1)
 This is a speed demand signal, also known as a
communications ‘comms' throttle
 CAN is the communication network between
intelligent electronic devices ( several ECM’s)
used on an machine application
 Uses a version of CAN that conforms to an
international standard known as SAE J1939
 Application control, monitoring and diagnostics is
possible using SAE J1939
 Slide 146
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Mode Selection
 A mode defines a fuel limit map, a rated speed and
a droop value for each throttle input
 This feature provides the ability to select up to four
different modes of operation
 A mode defines:
 one of 4 ratings
 a droop value for each throttle input, 0 - 10%
 Mode selection is controlled by 2 switched inputs
 Slide 147
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Mode Selection Wiring

 Slide 148
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Typical Mode Selection Examples

Mode Mode Mode Comms

Mode Throttle 1 Throttle 2
Selection Selection Selection Rating Tools
Selection Valid Droop Droop
Switch Switch Switch Number Droop
Number Percentage Percentage
Input 1 Input 2 Input 3 Percentage
Open Open Open 0 Yes 1 10 5 0
Open Open Closed 1 Yes 1 5 2 0
Open Closed Open 2 Yes 2 10 5 0
Open Closed Closed 3 Yes 2 5 2 0
Closed Open Open 4 Yes 3 10 5 0
Closed Open Closed 5 Yes 3 5 2 0
Closed Closed Open 6 Yes 4 2 2 0
Closed Closed Closed 7 Yes 4 0 0 0
 Slide 149
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SAE J1939 Datalink

 Advantages:
 Uses less wiring

 Lower weight

 Lower cost

 Fewer connections

 Increased Reliability

 Easier to install

 Improved quality of signal

 Can transfer large amounts of Data

 Slide 150
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Example of SAE J1939 Wiring

Note. CAN wiring must be twisted

Nodes

DCR GEM TSC1

Address 249 Address 23 Address 3

Data Bus
120 Ohm

ECM

DCR, Diagnostic Code Reader

GEM, Generic Engine Monitor
TSC, Torque Speed Control
 Slide 151
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J1939 Datalink

 Example of J1939 CAN Communications

 Transmission ECM to engine ECM:
 ‘Requests’ an engine speed change for a
period of time while transmission changes
gear.
 Engine ECM to machine ECM:
 ‘Broadcasts’ engine parameters (e.g.
engine speed, oil pressure, coolant temp)
 Slide 152
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J1939 Datalink Fault Finding

 Do make sure
“CAN high +”
“CAN low -” are wired correctly
 Do use 120 terminating resistors
 Do Make sure that no short circuits are
present
 Do Check for possible electrical interference