M T L L E A R N IN G C E N T E R

Engine - 3176C
• 6 cylinder in line
M T L L E A R N IN G C E N T E R

• Total displacement : 10.3L

• Electronic unit injector system
• Increased control of timing and fuel/air ratio control
• Fuel injector timing and duration is determine by the
ECM based on input from various parameters
measured
• Refer to RENR1235 page 1-3 & 1-4
 M T L L E A R N IN G C E N T E R

Engine Nameplate
M T L L E A R N IN G C E N T E R

Muffler
Inlet manifold
To ATAAC
M T L L E A R N IN G C E N T E R

Line to pressurize the Hydraulic tank

 M T L L E A R N IN G C E N T E R

Engine Oil Cooler

M T L L E A R N IN G C E N T E R Engine Nameplate
M T L L E A R N IN G C E N T E R
Close View of Engine Nameplate
M T L L E A R N IN G C E N T E R
Engine Identification Number Plate
 Engine - 3176C

• Air Inlet and Exhaust System:

M T L L E A R N IN G C E N T E R

– comprises the Turbocharger, valve mechanism, intake and

exhaust valves and manifold
– some engine utilized the waste gate to boost the
turbocharger effectiveness over lower engine speeds
– the waste gate is controlled by boost pressure and opening
pressure is around 24 +0.5 psi
 The boost pressure controls the maximum rpm of the
turbocharger, because the boost pressure controls
the position of the waste gate.
M T L L E A R N IN G C E N T E R

The waste gate controls the amount of exhaust gas that

is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the
turbocharger.
When the engine operates in conditions of low boost
(lug), a spring presses against a diaphragm in the
canister.
The actuating rod will move and the waste gate will
close.
 Then, the turbocharger can operate at maximum
performance.
When the boost pressure increases against the diaphragm
in the canister, the waste gate will open.
M T L L E A R N IN G C E N T E R

The rpm of the turbocharger becomes limited.

The rpm limitation occurs because a portion of the
exhaust gases bypass the turbine wheel of the
turbocharger.
The following levels of boost pressure indicate a
problem with the waste gate:
� Too high at full load conditions
� Too low at all lug conditions
 Note: The housing assembly for the wastegate is preset
at the factory and no adjustments can be made.
The following factors also affect the maximum rpm of
M T L L E A R N IN G C E N T E R

the turbocharger:
� The engine rating
� The horsepower demand on the engine
� The high idle rpm
� The height above sea level for engine operation
� Inlet air restriction
� Exhaust system restriction
 Air filter
M T L L E A R N IN G C E N T E R

Water
separator
cum
primary
filter (10
micron)
 Pre-cleaner

Water Separator
M T L L E A R N IN G C E N T E R

Primary and Secondary air filters

 Inlet manifold pressure
Sensor
M T L L E A R N IN G C E N T E R

Air
Temperature
Sensor

Intake manifold
Exhaust manifold
 Coolant return to Radiator

Coolant
temperature
sensor
M T L L E A R N IN G C E N T E R

Timing and
calibration
probe

From
aftercooler

To aftercooler

Refer to page 1-5 & 1-6, RENR 1235

 Fuel hand priming pump Breather

Vent
M T L L E A R N IN G C E N T E R

line
Atmospheric
pressure sensor

Inlet manifold pressure

Inlet air temperature Oil filler plug Dipstick

 AIR INLET & EXHAUST SYSTEM TEST
M T L L E A R N IN G C E N T E R

Air inlet restriction

Exhaust restriction
 M T L L E A R N IN G C E N T E R

Refer to RENR 1222

, page 14
M T L L E A R N IN G C E N T E R
Engine - 3176C
 Engine - 3176C
• Rated Fuel Pos:
M T L L E A R N IN G C E N T E R

– It is the limit based on the horsepower rating

of the engine
– It is programmed by factory into the
Personality module and cannot be
programmed in the field
– similar to rack stop and torque spring on
mechanically governed engine
– provides a typical horsepower and torque
curves for a specific engine family and
rating
 Engine - 3176C

• Fuel system – page 14

M T L L E A R N IN G C E N T E R

• Fuel is filter through the primary and

secondary fuel filters of 10 and 2 micron filter
size.
• Fuel pump supply fuel when engine is started,
excess fuel is supplied to the fuel injectors to
help cool the ECM and Injector body
M T L L E A R N IN G C E N T E R
Fuel Supply
M T L L E A R N IN G C E N T E R
Primary Filter
M T L L E A R N IN G C E N T E R

1. Transfer Pump
2. Secondary Filter
M T L L E A R N IN G C E N T E R
Secondary Fuel Filter
M T L L E A R N IN G C E N T E R
Fuel Pressure Regulator
M T L L E A R N IN G C E N T E R
ECM

Function of ECM
-Received all signals from sensors
-Energizes injector solenoids to control timing and
engine speed.
M T L L E A R N IN G C E N T E R
Fuel Supply
 Engine - 3176C

• The fuel injectors are electronically controlled

M T L L E A R N IN G C E N T E R

and mechanically actuated

• Electronic control areas are :
– ECM, PM, sensors, unit injectors, harness and
connectors
• Mechanically actuation involves :
– camshaft, lifter, push-rod, rocker arm assembly
and adjusting nut
M T L L E A R N IN G C E N T E R
Injector Components
M T L L E A R N IN G C E N T E R
Injector Components
 Engine - 3176C
• Fuel injector operation:
M T L L E A R N IN G C E N T E R

• Injector plunger movement downward by the rocker assembly

cuts off the supply of fuel into the injector.
• Energizing the injector solenoid closes the return port and
allows fuel pressure within the injector to build up
• Fuel begins injection when pressure of fuel reaches 5000 psi
and cease injection when fuel pressure falls to 3500 psi
• Length of fuel injection is dependent on the governor logic
programmed into the ECM
M T L L E A R N IN G C E N T E R
Mechanical Actuation
M T L L E A R N IN G C E N T E R

EUI Injector Components

M T L L E A R N IN G C E N T E R

Cartridge Valve Assembly

 Engine - 3176C
• Fuel injection
M T L L E A R N IN G C E N T E R

– only when ECM sends 105 volt signal to

energize solenoid to close the return passage
– amount of fuel injected depends on the
duration the ECM energizes the solenoid
– FRC Fuel Pos limits the amount of fuel that
can be injected
– FRC Fuel Pos is determined by the boost air
pressure
M T L L E A R N IN G C E N T E R
Closed Poppet
M T L L E A R N IN G C E N T E R

Pre-injection
M T L L E A R N IN G C E N T E R

Start of Injection
M T L L E A R N IN G C E N T E R

Injection
M T L L E A R N IN G C E N T E R

End of Injection
 Fuel Injection Control System
M T L L E A R N IN G C E N T E R

Varying Start of injection controls fuel

timing
Varying end of injection or change of
duration control fuel quantity.
M T L L E A R N IN G C E N T E R
Electronic Governor
 M T L L E A R N IN G C E N T E R

filter
Pump
Priming

Fuel Secondary
 Fuel cooling
Engine
Starter
M T L L E A R N IN G C E N T E R

Machine Wiring
harness

Engine Wiring
harness

ECM
 Left side of engine
M T L L E A R N IN G C E N T E R

Rear
End
of
Engine

Fuel Hoses
M T L L E A R N IN G C E N T E R
Fuel temperature sensor
 Engine - 3176C

• Lubrication System:
M T L L E A R N IN G C E N T E R

– Filtered oil at 110 deg C is supplied to the engine

at about 40 psi during rated engine operating
condition
– High pressure relief valve is set at 100 psi
– T/C bearings are lubricated by oil taken direct
from the main oil galley and return by gravity back
to the sump
 Engine - 3176C
M T L L E A R N IN G C E N T E R

Signal line to operate

pump bypass valve

Bypass filter of 5 micron opens at 25 psi

Returns 5% of oil flow back t the sump
M T L L E A R N IN G C E N T E R

Lube line
to lube filter

Hydraulic line

Fuel Secondary filter

 Lube line to and from lube filter

Supply line to fan pump

M T L L E A R N IN G C E N T E R

From Fan
cooling pump

To tank
M T L L E A R N IN G C E N T E R

E/O Filter
 Engine -3176C :Cooling system
Radiator • 30% of ethylene glycol is
recommended to keep cavitation
temperature range high enough for
M T L L E A R N IN G C E N T E R

efficient performance.
Thermostat housing
Outlet temperature
• Coolant pump is driven at 1.17
regulation times engine speed
• ELC is recommended for the
cooling system

40%
Engine oil
cooler
60%

Return Passage Supply passage

M T L L E A R N IN G C E N T E R
Fan pump Cooling relief valve
M T L L E A R N IN G C E N T E R

valve
Fan pump
Cooling relief
M T L L E A R N IN G C E N T E R

sensor
Coolant temperature
 Fan motor case drain
M T L L E A R N IN G C E N T E R

Makeup Valve

Fan Motor
 Hydraulic oil to fan motor
M T L L E A R N IN G C E N T E R

Hydraulic return to tank

 Fuel Pressure
fitting Injector solenoid
harness
M T L L E A R N IN G C E N T E R

Fuel temperature
Sensor
M T L L E A R N IN G C E N T E R

Air-con compressor
M T L L E A R N IN G C E N T E R

Fan(Cooling) Pump
Regulator
Fan Pump (Cooling)
M T L L E A R N IN G C E N T E R
AIR-Con Compressor
 Engine - 3176C

• Built-in diagnostics alert operators via on

M T L L E A R N IN G C E N T E R

board dashboard mounted “check engine” light

• Caterpillar service tool is used to read the
numerical code of the faulty component or
condition
• Intermittent faults are logged and stored in the
memory
M T L L E A R N IN G C E N T E R

CAT Data link

- Enable ECM to communicate with each
other and with ET Service tool.
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R

ATA Data link

- used for flash programming only.
 Electronic Control System Components
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
ADEM - II
 ECM Monitoring
M T L L E A R N IN G C E N T E R

• Off Mode
• Derate Mode
• Shutdown Mode
 Customer Specified
Programmable Parameters
M T L L E A R N IN G C E N T E R
 ECM Event Codes
• Warn that a situation could become a
problem
M T L L E A R N IN G C E N T E R

• Insight on how vehicle is being operated:

– Over speed
– Quick stops
– Low oil pressure
– High manifold temperature
– High coolant temperature
– Low coolant level
– Engine over speed
 ADEM 2000 Features

• ECM Controls:
M T L L E A R N IN G C E N T E R

– Fuel Delivery
– Injection Pressure
– Injection Timing
• Personality Mode:
– FLASH program
software
– Updates using ET
Personality Module
-Contains software and all fuel setting
information (Torque rise & FRC)
To determine how engine perform.
M T L L E A R N IN G C E N T E R
ADEM Management Information
 Engine Harness Starter Pinion Starter Motor
M T L L E A R N IN G C E N T E R

Machine
Harness
 Engine - 3176C
• Starting the engine and cold mode
M T L L E A R N IN G C E N T E R

– ECM automatically provide the correct amount of fuel

during engine start-up
– Excessive use of ether can cause damage to piston and
rings
– Engine control system operates at cold mode if coolant
temperature is less than 17 deg C
– Engine low idle is increased to 800 rpm during cold mode
until coolant temperature is above 28 deg C or 12 minutes
later( whichever comes first)
M T L L E A R N IN G C E N T E R

Starter motor pinion Starter motor

 Alternator

From Air Cooler

M T L L E A R N IN G C E N T E R

Fuel
pressure
tap

Crankcase breather pipe

 M T L L E A R N IN G C E N T E R

Fan pump

Alternator
 M T L L E A R N IN G C E N T E R

Line to Relief valve

 Engine - 3176C

• Electronic control system components layout:

M T L L E A R N IN G C E N T E R

Page 1-4, RENR 1235

• Electronic control system is made up of 3
types of electronic components, input, control
and output
• Wire harness and connectors act to link the
different components together
 Electronic Sensors and Systems
M T L L E A R N IN G C E N T E R

1. Pressure Sensor
2. Temperature Sensor
3. Position Sensor
4. Speed Sensor
 Electronic Component Sensors
M T L L E A R N IN G C E N T E R

• Speed Sensors
– ADEM II Engine Speed/Position
– ADEM III (2000) Engine Speed/Position
– Vehicle Speed
 Electronic Component Sensors

• Temperature Sensors:
M T L L E A R N IN G C E N T E R

– Coolant
– Oil
– Intake Air
– Exhaust
– Fuel
 Electronic Component Sensors
• Pressure Sensors:
M T L L E A R N IN G C E N T E R

– Oil
– Fuel
– Boost
– Atmospheric
 Electronic Component Sensors
• Active Sensors
M T L L E A R N IN G C E N T E R

• Passive Sensors
• Position Sensors
– Coolant Level
– Throttle Position
 ADEM III Pressure Sensors
M T L L E A R N IN G C E N T E R

• Atmosphere
• Oil
• Boost
• Fuel
• IAP (HEUI)
 Pressure Sensors
M T L L E A R N IN G C E N T E R

Refer to RENR1235, page 5-40 to 5-59

M T L L E A R N IN G C E N T E R

5-47
Atmospheric Pressure Sensor
M T L L E A R N IN G C E N T E R
Oil Pressure Sensor

5-53
M T L L E A R N IN G C E N T E R

Boost Pressure Sensor

5-40
 Temperature Sensors
M T L L E A R N IN G C E N T E R

• Coolant
• Intake air
• Fuel
• Oil
• Exhaust
M T L L E A R N IN G C E N T E R
Temperature Sensors
 ADEM II Active Coolant
Temperature Sensor
M T L L E A R N IN G C E N T E R

5-34
 ADEM II Air Inlet Temperature
Sensor
M T L L E A R N IN G C E N T E R

5-74
M T L L E A R N IN G C E N T E R

Fuel Temperature Sensor

5-68
 Throttle Position Sensor
M T L L E A R N IN G C E N T E R

Throttle
Position Sensor

Engine Harness

ECM
M T L L E A R N IN G C E N T E R
Coolant Level Sensor
M T L L E A R N IN G C E N T E R
Coolant Sensor Circuitry
M T L L E A R N IN G C E N T E R
PWM Signals
 Speed Timing Sensor
M T L L E A R N IN G C E N T E R

ADEM II
ECM
3176
“Fat”
ECM

5-21
 Engine Speed Timing Sensor
M T L L E A R N IN G C E N T E R

Functions
- Speed measuring
- Timing measuring
- Cylinder identification
M T L L E A R N IN G C E N T E R
Engine Speed Timing Sensor
M T L L E A R N IN G C E N T E R
Speed/Timing Sensors
 Engine Speed/Timing Sensor
Circuit - Test
M T L L E A R N IN G C E N T E R

Refer to 5-22
 Speed/Timing Sensor - Calibrate
M T L L E A R N IN G C E N T E R

When to calibrate
- Sensor replacement
- Timing adjustment
- Timing wheel/gear replacement
- ECM replacement

Refer to page 6-3

M T L L E A R N IN G C E N T E R
Timing Wheel
 Timing Calibration Probe
Installation
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
Crankshaft Machined Slot
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
 Power Supply
M T L L E A R N IN G C E N T E R

• EUI System:
– External Power Supply
• ECM Power Supply – 24 V
– Internal Power Supply
• Injector Power Supply – 105V
• Analog Sensor Power Supply – 5V
• Digital Sensor Power Supply – 8V
• Refer to page 5-6
M T L L E A R N IN G C E N T E R
ECM Power Supply Circuit
 ECM and Machine Interface
Connectors
M T L L E A R N IN G C E N T E R
 Injector Power Supply
M T L L E A R N IN G C E N T E R

Refer to page 5-28

 Analog Sensor Power Supply
M T L L E A R N IN G C E N T E R

Refer to page 5-60

 M T L L E A R N IN G C E N T E R

5-65
Engine Shutdown System
 User Defined Shutdown Circuit
M T L L E A R N IN G C E N T E R

5-65
M T L L E A R N IN G C E N T E R
Ether Injection System
M T L L E A R N IN G C E N T E R

(EUI)
Electronic Fuel System
M T L L E A R N IN G C E N T E R
Injection Current Waveform
 System Controls
M T L L E A R N IN G C E N T E R

• Fuel System Limits:

– Maximum horsepower
– Torque limit
– Fuel ratio control
– Cold mode limit
– Cranking limit
– Acceleration delay during start up
 System Controls
M T L L E A R N IN G C E N T E R

• Fuel System Cold Modes:

– Speed controls
– Fuel limiting
– Injection timing
– Ether injection
 System Controls

• Derates:
M T L L E A R N IN G C E N T E R

– Automatic altitude compensation

– Automatic filter compensation
– Engine warning derate:
• Loss of boost sensor output
– Fuel temperature compensation
 Electronic Trim (E-Trim)
Delivery Tolerance
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
E-Trim Program
 E-Trim Injector Value
M T L L E A R N IN G C E N T E R

Four Injector Tests

- Solenoid test, manual cylinder cut out test
- Automatic cylinder cut out test
- Active/ logged fault screen
M T L L E A R N IN G C E N T E R
Programming New Injector
 Pressure Sensor Calibration
M T L L E A R N IN G C E N T E R

Pressure sensors calibrations

- Using key switch (key switch “on” for 5 sec)
- Using ET
 Equipments for Flash Programming

PC or Laptop
M T L L E A R N IN G C E N T E R

ET software
Flash files
Communication Adaptor
Machine to com-adaptor cable
Com-adaptor to PC cable
M T L L E A R N IN G C E N T E R
Air in Fuel Test
M T L L E A R N IN G C E N T E R
Engine Pressure Group
M T L L E A R N IN G C E N T E R

Pressure Gauge
Connecting Fuel
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R
M T L L E A R N IN G C E N T E R