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3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

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Welcome:apache03
Product:GENERATORSET
Model:3412CGENERATORSET4BZ
Configuration:3412GeneratorSet4BZ00001UP

SystemsOperation
3412GeneratorSetEngines
MediaNumberRENR138806

PublicationDate01/08/2015

DateUpdated26/08/2015
i02492531

ElectronicControlSystemComponents
SMCS1900

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Illustration1

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

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Rightsideview
(1)ElectronicControlModule(ECM)
(2)Coolantlevelsensorconnector
(3)Rackpositionsensor
(4)Boostpressuresensorconnector
(5)Enginecoolanttemperaturesensor
(6)Engineoilpressuresensor
(7)Speedsensor
(8)Atmosphericpressuresensor

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Illustration2

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ViewAA
(9)Fuelshutoffsolenoid
(10)Racksolenoid(BTM)
(11)ATAdatalink

Theelectroniccontrolsystemisdesignedintotheengine'sfuelsystem.Thesystemisdesignedtoelectronically
controlthedeliveryoffuelandinjectiontiming.
Theengineusesthefollowingthreetypesofelectroniccomponents:
Inputcomponent
Controlcomponent
Outputcomponent
AninputcomponentisonethatsendsanelectricalsignaltotheECMofthesystem.Thesignalthatissentvaries
ineitherofthefollowingways:
Voltage
Frequency
TheECMinterpretsthesignalfromtheinputcomponentasinformationaboutthecondition,environment,or
operationoftheengine.
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Acontrolcomponent(ECM)receivestheinputsignalsfromtheinputcomponents.Electroniccircuitsinsidethe
controlcomponentevaluatethesignalsfromtheinputcomponents.Theseelectroniccircuitsalsosupply
electricalenergytotheoutputcomponentsofthesystem.Theelectricalenergythatissuppliedtotheoutput
componentsisbasedonpredeterminedcombinationsofinputsignalvalues.
Anoutputcomponentisonethatisoperatedbyacontrolmodule.Theoutputcomponentreceiveselectrical
energyfromthecontrolgroup.Theoutputcomponentusesthatelectricalenergyinoneoftwoways.Theoutput
componentcanusethatelectricalenergyinordertoperformwork.Asanexample,amovingsolenoidplunger
willperformwork.Theoutputcomponentcanusethatelectricalenergyinordertoprovideinformation.Asan
example,adashpanellightoranalarmwillprovideinformationtotheoperatoroftheengine.
Theseelectroniccomponentsprovidetheabilitytoelectronicallycontroltheengineoperation.Engineswith
electroniccontrolsofferthefollowingadvantages:
Improvementinperformance
Improvementinfuelconsumption
Reductioninemissionslevels
VarioussensorsfeedenginedatatotheECM.Thesesensorsmodifythefollowingfunctions:
Boostpressure
Engineoilpressure
Enginespeed
Fuelrackposition
Throttleposition
On/offignition
TheECMprocessesthedata.Then,theECMsendselectronicsignalstothefuelinjectionsolenoids.Thefuel
injectionsolenoidsmovethefuelrack.Thiswilloptimizetheefficiencyandtheperformanceoftheengine.
Theelectronicenginecontrolsystemalsohasthefollowingbuiltinfunctions:
Engineoverspeed
Onboarddiagnostics

DataLink
Adatalinkisusedforthefollowingitems:
Communicateengineinformation.
CommunicatewithCaterpillarElectronicTechnicianCatET.
Calibratetheelectronicenginecontrolsystem.
Troubleshoottheelectronicenginecontrolsystem.
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Programtheelectronicenginecontrolsystem.
TheelectronicenginecontrolsystemincludesaDataLink.TheDataLinkcommunicateswithother
microprocessorbaseddevices.ThesedevicesarecompatiblewithSAERecommendedPracticesJ1708and
J1587.TheDataLinkcanreducetheduplicationofsensorsbyallowingthecontrolstoshareinformation.
TheDataLinkisusedtocommunicateengineinformationtootherelectroniccontrolsystems.Also,theData
LinkcaninterfacewithCatET.
TheDataLinkmonitorsengineinformation.TheengineinformationthatisavailableontheDataLinkincludes
thefollowinginformation:
Boostpressure
Engineidentification
Enginespeed
Oilpressure
Rackposition
Statusanddiagnosticinformation
Throttleposition
TheCatETisusedtoprogramthecustomerspecifiedparameters.
TheCatETisonemethodofprogrammingthecustomerspecifiedparametersthatareselectedbythecustomer.
ThetoolplugsintotheDataLinkConnector.ThisallowsthetooltocommunicatewiththeECM.Also,theCat
ETcanbeusedtodisplaytherealtimevaluesofalltheinformationavailableontheDataLink.Thiswillhelp
diagnoseengineproblems.

SystemDiagnosticCodes
Table1
DiagnosticFlashCodes
FlashCode

DescriptionofCode

21

SensorSupplyVoltageFault

22

RackPositionSensorFault

24

OilPressureSensorFault

25

BoostPressureSensorFault

26

AtmosphericPressureSensorFault

27

CoolantTemperatureSensorFault

32

ThrottlePositionSensorFault

33

EngineRPMSignalFault

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34

LossOfEngineSpeedSignal

35

EngineOverspeedWarning

42

CheckBoostSensorCalibration

43

RackSubsystemFault

45

ShutoffSolenoidFault

46

LowEngineOilPressureWarning

48

ExcessiveEnginePower

51

IntermittentBatteryPowertoECM

52

ECMorPersonalityModuleFault

53

ECMFault

55

NoDetectedFaults

56

CheckCustomerorSystemParameters

61

HighCoolantTemperatureWarning

62

LowCoolantTemperatureWarning

RefertoElectronicTroubleshootingGuideforacompleteexplanationoftheDiagnosticCodes.

ElectronicControlModule(ECM)andPersonalityModule

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Illustration3

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ECMandpersonalitymodule
(1)ElectronicControlModule(ECM)
(2)Fueloutlet
(3)Fuelinlet
(4)Personalitymodule

The3412CgeneratorsetengineusesanECMmicroprocessor.TheECMismountedonthetopofthe
aftercoolerhousing.TheECM(1)andthepersonalitymodule(4)arecooledbyfuel.Thefuelcirculatesthrough
amanifoldbetweentwocircuitboardsinthecontrolmodule.Thefuelentersthecontrolmodulefromthefuel
transferpump.Thefuelentersthecontrolmodulethroughthefuelinlet(3).Then,thefuelexitsthecontrol
modulethroughthefueloutlet(2).
Theinputsandtheoutputstothecontrolmodulearedesignedtowithstandtheshortcircuitstothebattery
voltagewithoutdamagetothecontrol.Theelectronicenginecontrolsystemhasthefollowingfeaturesthatare
designedintothesystem.
Resistancetoradiofrequency
Resistancetoelectromagneticinterference
Thesystemhaspassedtestsforinterferencethatiscausedbytwowayradiosandbyswitchingnoise.
TheECMpowersupplyprovideselectricalpowertoallenginemountedsensorsandactuators.Thefollowing
precautionshavebeendesignedintotheECM.
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Reversevoltagepolarityprotection
Vesselpowersystemvoltageswingsorsurgesduetosuddenalternatorload
Inadditiontoactingasapowersupply,theECMalsomonitorsallsensorinputs.TheECMprovidesthecorrect
outputs.Also,theECMensuresthedesiredengineoperation.
TheECMmemorystoresandidentifiesaselectedfactoryenginerating.Thememoryalsocontainsapersonality
moduleidentificationcode.Thiscodeisusedtoavoidunauthorizedtamperingorswitchingofpersonality
modulesandotherpertinentmanufacturinginformation.
Thewiringharnessprovidescommunicationstothefollowingareas:
Varioussensors
Datalinkconnector
Engineconnectors
ThepersonalitymoduleisattachedtotheECM.Thepersonalitymoduleprovidesalltheinstructionsnecessary
fortheECMtofunction.Thepersonalitymodulecontainstheengineperformanceinformationandthe
certificationinformation.Thiscertificationinformationincludesfuelratioinformationandrackcontrolmapsfor
aparticularratingsgroupthatutilizescommonenginecomponents.
TheECMisprogrammedtoperformthefollowingfunctions:
Diagnostictestsonallinputs
Diagnostictestsonalloutputs
Willseparateafaulttoaspecificcircuit
Onceafaultisdetected,thefaultcanbedisplayedonadiagnosticlamp.Thediagnosticcodecanbereadby
usingCatET.Amultimetercanbeusedtocheckmostproblems.Also,amultimetercanbeusedtotroubleshoot
mostproblems.TheECMwilleitherlogorrecordmostdiagnosticcodesthataregeneratedduringengine
operation.TheseloggedorintermittentcodescanbereadbyCatET.

ThrottleControlSensor
Athrottlecontrolsensorisusedtointerfacewiththethrottle.Thethrottlecontrolsensoroutputisaconstant
frequency,pulsewidthmodulation(PWM)signalratherthanananalogvoltage.Refertopulsewidthmodulation
intheglossary.ThePWMsignalovercomestheseriouserrorsthatcanresultfromanalogsignals.Theseerrors
occurfromthefollowingproblems.
Leakagebetweenpins
Contaminationinthewiringharness
Contaminationintheconnectors
TheenginereturnstolowidleifthePWMsignalisinvalidduetoabrokenorshortedwire.

FuelRackControls
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Illustration4

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Crosssectionviewoftherackhousing
(1)Shutoffsolenoid
(2)Racksolenoid(BTM)
(3)Fuelrackservo

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Illustration5

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Crosssectionviewofrackpositionsensor
(4)Fuelrack
(5)Rackpositionsensor
(6)Shutoffoverrideshaftandleverassembly(manualshutoff)

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Illustration6

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Crosssectionviewofenginespeedsensor
(7)Flywheelstartergear
(8)Enginespeedsensor

Engineoilpressureisusedtomovethefuelrack.Anelectronicallyactuatedracksolenoid(BTM)(2)controlsa
doubleactinghydraulicservo.Theservodirectsengineoilpressuretoeithersideofapistonthatisconnectedto
thefuelrack.Theoilpressuremovesthepiston.Thepistonmovesthefuelrack.
Theservogroupisagerotortypeoilpump.Theservogroupincreasesthepressureoftheengineoilthatis
suppliedtothegovernor.Theincreasedoilpressureallowsabetterregulationofenginespeedduringtherapid
applicationortheremovalofheavyloadsontheengine.
Theracksolenoid(BTM)(2)isinstalledinthesideoftherackactuatorhousingonthefuelinjectionpump.The
racksolenoid(BTM)(2)iscontrolledbytheECM.Theleveroftheracksolenoid(BTM)isengagedinacollar
ontherackservovalve.Theracksolenoid(BTM)isspringloadedtowardthefueloffpositionandmustreceive
apositivevoltageinordertomoveinthefuelonposition.
Rackpositionsensor(5)islocatedinsidetherackactuatorhousing.Therackpositionsensorisattachedtothe
fuelrackbyamagnet.Therackpositionsensorisalinearpotentiometerthatprovidesaccuratefeedback
informationfortheECM.
Inadditiontotherackpositiondata,theECMreceivesdatafromothersensorsthatarelocatedintherack
actuatorhousing.Theenginespeedsensor(8)istriggeredbyradialslotsontheflywheel.Oilpressure,inletair
pressure,andtheboostpressuresensorsaremountedontheengine.ThesesensorsareconnectedtotheECM.
TheECMwilllimitenginespeedandpoweroutputoftheengineiflowoilpressureoccurs.Whenthereisa
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changeinboostand/orinletairpressure,thecontrolmoduleadjuststhequantityoffuelorthetimingoffuelthat
isdeliveredtotheengine.
TheECMoperatesanenergizedtoruntypeshutoffsolenoid(1).Iftheracksolenoid(BTM)(2)isunableto
movethefuelracktothefueloffposition,theshutoffsolenoidwillapplyanadditionforceonthefuelrackto
movetheracktothefueloffposition.Amanualshutoff(6)(shutoffoverrideshaftandleverassembly)is
provided.Themanualshutoffcontrolshaftisspringloadedtoaneutralposition.
Iftheshutoffsolenoidfailstoenergize,thesolenoidoverridemaybeusedtomovetheshutoffleverawayfrom
thefuelrackservo(3).Thiswillallowtheracksolenoid(BTM)tomovethefuelrackeventhoughtheshutoff
solenoidisnotenergized.
Themanualshutoffmaybeusedtoshutdowntheenginewiththeshutoffsolenoidenergizedandpower
maintainedtotheECM.Thismethodofshutdownisusedinsometroubleshootingprocedures.
Themechanicalfuelratiocontrol,torquecontrolgroup,andvariousadjustmentscrewshavebeeneliminated.
Theelectroniccontrolmoduleperformsallofthesefunctions.Thecontrolmoduleadjuststheenginepowerand
thetorquerise.Thiscompensatesfortheoperationoftheenginethateitherhaspluggedaircleanersortolimit
theamountofsmoke.
TheamountoffuelthatisneededbytheenginetomaintainadesiredrpmisdeterminedbytheECM.Withthe
enginerunningatadesiredspeed,theenginespeedwilldecreasewhenanadditionalloadisapplied.Thesignal
fromtheenginespeedsensor(8)totheECMchanges.Thecontrolmoduleperformsthefollowingtasks:
Receivesthesignalandotherdata
Processesallthedata
Sendsapositivevoltagetotheracksolenoid(BTM)
Theracksolenoid(BTM)movesthevalveinfuelrackservo(3).Thiswillcausethefuelracktomoveinthe
FuelOndirection.Theincreaseinfueltotheenginewillincreaseenginespeed.Thisactionwillcontinueuntil
theengineisagainrunningatthedesiredspeedoruntiltherackpositionhasincreaseduptoarackposition
limit.
Withtheenginerunningatadesiredspeed,theenginespeedwillincreasewhentheloadisdecreased.TheECM
receivesthechangedsignalfromtheenginespeedsensor(8).TheECMreducestheelectricalsignalthatgoesto
theracksolenoid(BTM).Theracksolenoid(BTM)movesthevalveinthefuelrackservo(3).Thiswillmove
thefuelrackintheFuelOffdirection.Thedecreaseinfueltotheenginewilldecreaseenginespeed.Thisaction
willcontinueuntiltheengineisagainrunningatthedesiredspeed.
Theelectronicenginecontrolsystemallowstheenginetobecrankedandthenallowstheenginetostart.The
throttlecontrolisnotneeded.TheECMwillautomaticallyprovidetheenginewiththecorrectamountoffuel
thatisrequiredtostarttheengine.Sincesomeoilpressureisrequiredforthefuelrackservotomovethefuel
rack,electronicallycontrolledenginesmayrequireaslightlylongercrankingtimetostart.

GovernorServo

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Illustration7

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RackmovementtowardFullFuel
(1)Piston
(2)Cylinder
(3)Sleeve
(4)Valve
(5)Fuelrack
(A)Oilinlet
(B)Oiloutlet
(C)Oilpassage
(D)Oilpassage

Whentheracksolenoid(BTM)isenergized,theracksolenoid(BTM)movesvalve(4)totheleft.Thevalve
opensoiloutlet(B)andthevalveclosesoilpassage(D).Pressureoilfromoilinlet(A)pushespiston(1)and
fuelrack(5)totheleft.Oilbehindthepistongoesthroughoilpassage(C),alongvalve(4)andexitsthroughoil
outlet(B).

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Illustration8

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Norackmovement(constantenginespeed)
(1)Piston.(2)Cylinder.(3)Sleeve.(4)Valve.(5)Fuelrack.(A)Oilinlet.(B)Oiloutlet.(C)Oilpassage.(D)Oilpassage.
(1)Piston
(2)Cylinder
(3)Sleeve
(4)Valve
(5)Fuelrack
(A)Oilinlet
(B)Oiloutlet
(C)Oilpassage
(D)Oilpassage

Whenthedesiredenginespeedisreached,theracksolenoid(BTM)holdsvalve(4)inafixedposition.Piston
(1)movestotheleftuntilbothoiloutlet(B)andoilpassage(D)areblockedbyvalve(4).Oilistrappedinthe
chamberbehindpiston(1).Thiscreatesahydrauliclock.Thepistonandthefuelrackmovementisstopped.

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Illustration9

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Rackmovementtowardfueloff
(1)Piston
(2)Cylinder
(3)Sleeve
(4)Valve
(5)Fuelrack
(A)Oilinlet
(B)Oiloutlet
(C)Oilpassage
(D)Oilpassage

Whentheracksolenoid(BTM)isdeenergized,springforceinthesolenoidmovesvalve(4)totheright.The
valveclosesoiloutlet(B)andopensoilpassage(D).Pressureoilfromoilinlet(A)isnowonbothsidesof
piston(1).Theareaofthepistonisgreaterontheleftsidethantheareaofthepistonontherightside.Theforce
oftheoilisalsogreaterontheleftsideofthepiston.Thepistonandthefuelrack(5)movestotheright.
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