Elect Sect01 Span

Factores de Desempeño del Motor
CATERPILLAR
Miami Skills Acquisition Center
Manufacturing Test
Conditions
 Rated horsepower ± 3% occurs at SAE
J1995 conditions
– 35° API fuel density @ 60°F

– 85°F fuel temperature
– 110°F inlet manifold temperature - ATAAC
– 77 °F inlet air temperature - JWAC
– 29.61 inches of hg air pressure (test cell)
(30.50 inches of hg in field)
CATERPILLAR
Manufacturing Test
Conditions
 Used by all major engine OEM'S
 Any deviation from standard
affects available horsepower
CATERPILLAR
Sample Problem
 What horsepower should be
expected from a 3406C, rated 425
horsepower @ 2100 rpm, under the
following conditions?
– 40° API fuel density at 90° F

– 135° F fuel temperature at filter base
– 105° F inlet manifold temperature
– 30.05 inches of hg air pressure
CATERPILLAR
Sample Problem
Fuel density corrects to ??° API @ 60°F
Fuel density correction factor ????
Fuel temperature correction factor ????
Air temperature correction factor ????
Baro. pressure correction factor ????
Total correction factor ????
CATERPILLAR
Sample Problem
Fuel density corrects to 37.6° API @ 60°F
Fuel density correction factor ????
CATERPILLAR
Sample Problem
Fuel density correction factor 1.011
CATERPILLAR
Sample Problem
Fuel temperature correction factor 1.050
CATERPILLAR
Sample Problem
Air temperature correction factor 0.997
CATERPILLAR
Sample Problem
Baro. pressure correction factor 1.003
CATERPILLAR
Sample Problem
Baro. pressure correction factor 1.003
Total correction factor 1.062
CATERPILLAR
Sample Problem
So . . . what horsepower should be

expected from our example
3406C rated 425 hp @ 2100?
425 ÷ 1.062 = 400 horsepower
CATERPILLAR
Clase de Electrónica
Preguntas?
CATERPILLAR
Fuel Systems Overview -
Mechanical Governor
 As engine speed
increases,
flyweights move
linkage and fuel
rack in fuel off
direction
CATERPILLAR
Mechanical Governor
 As engine load
increases, rpm
decreases
 Governor spring
force overcomes
flyweight force
 Rack moves in
fuel on direction
CATERPILLAR
Mechanical Governor
 As load decreases,
rpm increases
 Fly weight force
overcomes spring
force
 Moves rack in fuel off
direction
CATERPILLAR
Mechanical Governor
 As the rack moves in
the fuel-on direction,
the scroll is rotated to
allow more fuel to be
injected
 As the rack moves in
the fuel-off direction,
the scroll is rotated to
allow less fuel to be
injected
CATERPILLAR
Fuel Systems Overview
CATERPILLAR
 Fuel fills barrel

 Plunger is moved
upward by the fuel
system camshaft
 Fill/Spill port is closed,
fuel is pressurized
 Fill/Spill port opens,
pressure is lost
CATERPILLAR
 The position of the

scroll:
– is controlled by the
fuel rack
– determines the
amount of fuel
injected
CATERPILLAR
 Types of fuel systems:

– Pump and lines
– Mechanical Unit Injector (MUI)
– Mechanically Actuated Electronic Unit
Injector (EUI)
– Hydraulically Actuated Electronic Unit
Injector (HEUI)
CATERPILLAR
Pump & Lines System
 Multi-plunger, high
pressure pump, fuel
lines & fuel nozzles
 Flyweights and
springs control fuel
rate and timing
 Can inject fuel from
5,000 to 17,000 PSI
CATERPILLAR
Pump & Lines System
 Limiting Factors:
– High pressure fuel
lines limit fuel
injection pressure
– Fuel rate & timing
control
CATERPILLAR
MUI System
 A unit injector is
positioned above each
cylinder
 A mechanically
actuated governor
controls fuel rate
(scroll metered) with
flyweights and springs
 Timing is fixed
CATERPILLAR
MUI System
 Advantages:
– High pressure fuel
lines are eliminated
– Injection pressure
up to 23,000 PSI
 Limiting Factors:
– No timing advance
– Mechanical
actuation &
governor control
CATERPILLAR
EUI System
positioned above each
cylinder
 An Electronic Control
Module (ECM) controls
fuel rate and timing
 Injectors are
mechanically actuated
by a camshaft
CATERPILLAR
EUI System
 Can inject fuel at
up to 30,000 PSI
 High pressure
fuel lines are
eliminated
CATERPILLAR
CATERPILLAR
CATERPILLAR
CATERPILLAR
CATERPILLAR
EUI - Injector Fill
 Without pressure
from the rocker arm,
a spring keeps the
plunger retracted
 Fuel flows into the
injector through the
fill / spill port, past
the poppet valve and
into the barrel
CATERPILLAR
EUI - Mechanical Stroke
 As the cam
rotates, it drives
the plunger
downward
 Until the ECM
signals the start
of injection, fuel
goes out the
fill / spill port
CATERPILLAR
EUI - Injection
 On a signal from
the ECM, the
solenoid closes
the poppet valve
 Pressure elevates
at the tip to the
5,500 psi needed
to unseat the
nozzle check / tip
 Injection begins
CATERPILLAR
EUI - Injection
 Fuel continues to
inject until the
ECM signals the
solenoid to open
the valve
 Injection timing
and duration is
controlled by the
ECM
CATERPILLAR
EUI Limitation
 Limiting Factor:
– Injection pressure
is dependent on
engine speed
(rpm)
CATERPILLAR
HEUI System
positioned above
each cylinder
 An Electronic
Control Module
(ECM) controls fuel
rate, timing, and
injection pressure
 The injector is
hydraulically
actuated
CATERPILLAR
HEUI System
 High pressure
fuel lines are
eliminated
 Can inject at up to
23,500 PSI
CATERPILLAR
HEUI System
 An advantage:
– Injection pressure is
infinitely controlled
between maximum
and minimum
pressure limits,
regardless of
engine speed
CATERPILLAR
HEUI Fuel System
CATERPILLAR
HEUI System - IAPCV
 The IAPCV (Injection
Actuation Pressure
Control Valve:
– Controls the HEUI oil
pressure
– Is part of the HEUI
hydraulic pump,
externally mounted
for easy service
– Has a large, externally
mounted electrical
solenoid for efficiency
and serviceability
CATERPILLAR
HEUI System - IAPCV
 The valve
receives current
from the ECM to
control the
hydraulic
pressure in the
HEUI system
CATERPILLAR
HEUI System - IAPCV
 Regulates the
pump pressure by
venting excess oil
flow to engine oil
sump.
CATERPILLAR
In the HEUI Fuel System
 High injection pressures give:
– lower particulate emissions
– improved fuel rate
– improved performance
 Injection rate shaping gives:
– lower NOx emissions
– reduced combustion noise
 Sharper end of injection gives:
– reduced particulate emissions
CATERPILLAR
CATERPILLAR
CATERPILLAR
Preguntas?
CATERPILLAR
Engine Model Numbers
 3208 Engine:
– 3 = Engine Product
– 2 = Relative Engine Size
» (3000, 3200, 3300, 3400, 3500, 3600)
– 08 = number of Cylinders
» Depending on engine family, could
be 04, 06, 08, 12, 16, 18, or 24
CATERPILLAR
 3116 Engine
– 3 = Engine Product
– 11 = 1.1 liters per cylinder, so:
» 3126 has 1.2 liters per cylinder
– 6 = number of cylinders (4 or 6)
CATERPILLAR
 C-10, 10 liter truck engine

– 10 liter in everything else is 3176C
 C-12, 12 liter truck engine
– 12 liter in everything else is 3196C
CATERPILLAR
 3406E was a 14.6 liter engine until 1998

 In 1998, 3406E was 14.6 or 15.8 liter for
truck
 3456 was the 15.8 liter in any non-truck
application
 14.6 liter and 15.8 liter became C-15 and
C-16 for truck, industrial applications
CATERPILLAR
 3000 Series Engines

– Perkins or MHI
(Mitsubishi Heavy Industries)
– As low as 20HP
 MAK Engines (Ex. 8CM25)
– Germany
– As high as 20,000 HP
CATERPILLAR
Engine Serial Numbers
 Our engines historically used

8-digit serial numbers in this
format:
– Number, letter, letter, five numbers
– Example: 2YG45313 or 8TC44185
CATERPILLAR
Engine Serial Numbers
 Some now have a different format:

– Letter, letter, letter, five numbers
– Example: CKM11284
 Another format started consists of any
combination in the first three characters
and last five will be numeric.
– Example: M2M12355
CATERPILLAR
Why Electronic Control?
 In the 1970’s, EPA exhaust emissions

standards were applied to automobiles.
 In the early 1980’s, similar EPA
requirements were applied to on-
highway trucks.
 Also in the 1980’s, EPA “Noise”
emissions were applied to the trucks.
CATERPILLAR
 Emission laws affect three key elements:
– Particulates
– NOx
– Sound
 CARB (California Air Resources Board)
limits sales of some engines.
 There are the EC (European
Commission) in Europe and equivalents
in other countries.
CATERPILLAR
 What is BLACK smoke?

(result of incomplete combustion)
 Charge shaping and injection pressure
are very significant
 Ability to change fuel injection timing
and duration very quickly is a must
 With Electronics we have decreased
noise, NOx, and particulates
CATERPILLAR
 Electronics allow increased:

– horsepower
– fuel economy
– horsepower to weight ratio.
 Electronics allow decreased:
– Noise
– NOx
– Particulates
CATERPILLAR
 To satisfy customers demand for:

– increased horsepower
– better fuel economy
– better reliability
– easier serviceability
CATERPILLAR
Caterpillar Electronically
Controlled Diesel Engine
3176C
CATERPILLAR
Electronically Controlled
Engines can . . .
 Indicate active faults, logged faults,
and logged events
 Identify major component failure
 Identify sensor and actuator short
or open circuits
CATERPILLAR
Electronically Controlled
Engines cannot . . .
 Troubleshoot themselves
 Identify marginal component
performance
 Identify inaccurate sensor readings
 Think for themselves
CATERPILLAR
Electronic Engine History
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3406B PEEC
3176 2YG
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3512 PEEC MUI 3512 PEEC MUI
3406B PEEC
3176 2YG
3508 EUI D11, 777

1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC
3176 2YG 3176 7LG
3508 EUI D11, 777

1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3406E Truck
3176 2YG 3176 7LG 3176B Truck
3508 EUI D11, 777

3512/16 EUI
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3406E Truck 3406E

3176 2YG 3176 7LG 3176B Truck 3176B
C-10
C-12
3508 EUI D11, 777
3512/16 EUI 3500B
3116 HEUI
3126 HEUI
3400 V HEUI
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3406E Truck 3406E 3406E

3176 2YG 3176 7LG 3176B Truck 3176B 3176B
C-10 C-10/3176C
C-12 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B
3116 HEUI 3116 HEUI

3126 HEUI 3126 HEUI
3400 V HEUI
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC
3406E Truck 3406E 3406E 3406E 14L

3176 2YG 3176 7LG 3176B Truck 3176B 3176B Added 16L
3456
C-10 C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B
3116 HEUI 3116 HEUI

3126 HEUI 3126 HEUI 3126B HEUI
3400 V HEUI
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L
3176 2YG 3176 7LG 3176B Truck 3176B 3176B Added 16L 3406E 16L
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B
3116 HEUI 3116 HEUI

3400 V HEUI
Perkins 3000
MAK
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000 ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15
3176 2YG 3176 7LG 3176B Truck 3176B 3176B Added 16L 3406E 16L C-16
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B
3116 HEUI 3116 HEUI

3400 V HEUI
Perkins 3000
MAK
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000 ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B
3116 HEUI 3116 HEUI C-9 HEUI

3126 HEUI 3126 HEUI 3126B HEUI 3126E HEUI
3400 V HEUI
Perkins 3000
MAK
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000 ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B

3400 V HEUI
Perkins 3000
MAK
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000 ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B

3400 V HEUI
Perkins 3000
MAK
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000 ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B

3400 V HEUI
1987 88 1990 1993 1995 1996 1998 1999 2000 2001 2002
3408 / 12 PEEC 3400 V PEEC

3600 PEEC

ADEM 2000 ADEM 2000
3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15
3456
C-10 C-10/3176C C-10/3176C C-10/3176C
C-12 C-12/3196 C-12/3196 C-12/3196
3508 EUI D11, 777
3512/16 EUI 3500B

3400 V HEUI
Perkins 3000
MAK
Preguntas?
CATERPILLAR

Elect Sect01 Span

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Factores de Desempeño del Motor

– 35° API fuel density @ 60°F

– 40° API fuel density at 90° F

So . . . what horsepower should be

425 ÷ 1.062 = 400 horsepower

 Fuel fills barrel

 The position of the

 Types of fuel systems:

 C-10, 10 liter truck engine

 3406E was a 14.6 liter engine until 1998

 3000 Series Engines

 Our engines historically used

 Some now have a different format:

 In the 1970’s, EPA exhaust emissions

 What is BLACK smoke?

 Electronics allow increased:

 To satisfy customers demand for:

3408 / 12 PEEC 3400 V PEEC

3508 EUI D11, 777

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3176 2YG 3176 7LG

3508 EUI D11, 777

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3508 EUI D11, 777

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3406E Truck 3406E

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3406E Truck 3406E 3406E

3116 HEUI 3116 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3406E Truck 3406E 3406E 3406E 14L

3116 HEUI 3116 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI C-9 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI C-9 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI C-9 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI C-9 HEUI

3408 / 12 PEEC 3400 V PEEC

3406B PEEC 3406C PEEC

3116 HEUI 3116 HEUI C-9 HEUI

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