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  • Service TrainingMeeting Guide 681 SERV1681-01

    January 2002

    TECHNICAL PRESENTATION

    3500 ENGINE CONTROLS

    ELECTRONIC UNIT INJECTION

    TOPRELUBRICATION

    PUMP

    + BATTERY

    GROUNDBOLT

    15 AMPBREAKER

    KEY STARTSWITCH

    24 V

    P20/J20SPEED/TIMING

    SENSOR

    J3/P3 MACHINEINTERFACE

    CONNECTOR

    COOLANTTEMPERATURE

    SENSOR

    8/12/16INJECTORS

    GROUND BOLT

    P26 T/C CONNECTOR

    J4/P4 THROUGHJ19/P19

    J2

    J1

    ECM

    UNFILTERED OILPRESSURE

    SENSOR

    AFTERCOOLERTEMPERATURE

    SENSOR

    CRANKCASEPRESSURE

    SENSOR

    J29/P29

    RIGHTTURBOCHARGERINLET PRESSURE

    SENSOR

    J25/P25

    LOW OILLEVEL

    SWITCH

    ATMOSPHERICPRESSURE

    SENSOR

    FUEL FILTERDIFFERENTIAL

    PRESSURE SWITCH

    TURBOCHARGEROUTLET

    PRESSURE SENSOR

    J23/P23

    COOLANTFLOW

    SWITCH

    FILTERED OILPRESSURE

    SENSOR

    J22/P22

    LEFTTURBOCHARGER

    EXHAUSTTEMPERATURE

    SENSOR

    RIGHTTURBOCHARGER

    EXHAUSTTEMPERATURE

    SENSOR

    LEFTTURBOCHARGERINLET PRESSURE

    SENSOR

    J28/P28

    J35/P35

    THROTTLEPOSITIONSENSOR

    THROTTLEBACK-UPSWITCH

    WASTEGATECONTROL SOLENOID

    USER DEFINED SHUTDOWN

    GROUNDLEVEL

    SHUTDOWNSWITCH

    BATTERY

    ENGINE FANCONTROLSOLENOID

    A/C ONSWITCH

    FAN SPEED SENSOR

    + BATTERY

    RELAYCYLINDER

    ENGINE

    ETHER START VALVE

    STARTINGAID SWITCH

    J21/P21

    J32/P32

    J105/P105

    J106/P106

    J47/P47

    P30/J30

    J27/P27

    J48/P48

    P84/J84

    P41/J41

    308-YL

    113-OR

    BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM

    ELECTRONIC SERVICETOOL CONNECTOR

    TO VIMS, EPTC II ORMONITORING SYSTEM

    DISCONNECTSWITCH

    OIL RENEWALCONTROL SOLENOID

    15 AMPBREAKER

    COOLANTTEMPERATURE

    SENSOR

    J4/P4 THROUGHJ19/P19

    RELAY

    J21/P21

    J47/P47

    J103/P103

    J113/P113

    P31/J31

  • 3500B ENGINE CONTROLSELECTRONIC UNIT INJECTION (EUI)

    MEETING GUIDE 681 SLIDES AND SCRIPT

    AUDIENCE

    Level II - Service personnel who understand the principles of engine systems operation, diagnosticequipment, and procedures for testing and adjusting.

    CONTENT

    This presentation is designed to prepare a service technician to identify the components, explain theirfunction, and service the 3500B Electronic Unit Injection (EUI) engines in current machineapplications.

    OBJECTIVES

    After learning the information in this presentation, the serviceman will be able to:

    1. Locate and identify the major electrical/electronic components in the 3500 EUI system.

    2. Explain the functions of the major electrical/electronic components in the 3500 EUI system.

    3. Trace the flow of fuel and oil through the fuel system.

    4. Trace the flow of current through the engine electrical system.

    PREREQUISITES

    Interactive Video Course "Fundamentals of Electrical Systems" (CD ROM) TEMV9002Service Technician Workbench Tutorial (CD ROM included with STW software) NEHS0812Caterpillar Machine Electronics Course (Five Modules) SEGV3001 - SEGV3005Caterpillar 3500B MEUI Fuel System (CD ROM) RENR1395

    Prior training in mechanical systems operation and testing and adjusting procedures for 3500B enginesshould be completed before participating in this training session. The participants should have PC skillsand have completed training in the current Windows operating system. Additionally, participantsshould have completed training in the most current Electronic Technician (ET) software.

    Estimated Time: 8 HoursVisuals: 101 (2 X 2) SlidesServiceman Handouts: 6 Drawings/Data SheetsForm: SERV1681-01Date: 1/2002

    2002 Caterpillar Inc.

  • REFERENCES

    Troubleshooting Guide "3500B Engines--Caterpillar Machines" SENR1128Specifications "3500B Engines--Caterpillar Machines" SENR1122Systems Operation, Testing and Adjusting "3500B Engines--Caterpillar Machines" SENR1123

    SUPPLEMENTARY TRAINING MATERIAL

    Brochure "Service Technician Workbench" NELG0028Brochure "Caterpillar Electronic Technician" NEDG6015

    Service Technician Workbench Tutorial (Included with STW software) NEHS08123500 and 3500B Series of Diesel Engines LERV1450Introduction to the 3500B Series Engine LEPV5149

    EUI SERVICE TOOLS

    Software and ManualsCaterpillar Service Tool Software/Getting Started Guide - Service Technician Workbench NEHS0796or Caterpillar Service Tool Software/Getting Started - Caterpillar Electronic Technician JEBD3003Caterpillar Service Tool Software/Users Manual- Communication Adapter II NEHS0758

    Mechanical ToolsEngine Turning Tool 9S-9082Injector Height Setting Tool Group 9U-5132Base for 9U-5132 (specific to 3500B) 125-2744

    Electronic ToolsLaptop computerCommunication Adapter II (Group) 171-4400Cable, PC to Communication Adapter 96-0055Cable, Communication Adapter to Machine 160-0133Caterpillar Digital Multimeter 146-4080Three Pin DT Breakout Harness 7X-6370Cable Probes 7X-1710Auxiliary ECM Power Supply Harness 167-9225Timing Calibration Probe (Magnetic Pickup) 6V-2197Timing Calibration Probe Adapter Sleeve 7X-1171Timing Calibration Probe Cable 7X-1695

    STMG 681 - 3 -1/02

  • TABLE OF CONTENTS

    INTRODUCTION ..................................................................................................................5Overview...........................................................................................................................6EUI Fuel System Components..........................................................................................8External Engine Views and Major Components .............................................................11Electronic Timing Components ......................................................................................18Machine Mounted Engine Components..........................................................................32Other Systems Controlled by the ECM ..........................................................................34

    ELECTRONIC CONTROL SYSTEM.................................................................................36Fuel Injection ..................................................................................................................39Fuel Injection Control System ........................................................................................41

    FUEL SUPPLY SYSTEM ....................................................................................................57Fuel Supply Circuit .........................................................................................................58Fuel Supply Components................................................................................................60

    SYSTEM POWER SUPPLIES.............................................................................................64ECM Power Supply ........................................................................................................65Speed/Timing Sensor Power Supply...............................................................................68Injector Power Supplies ..................................................................................................69Analog Sensor Power Supply .........................................................................................70Digital Sensor Power Supply ..........................................................................................71Wastegate Control Solenoid Power Supply ....................................................................72

    ELECTRONIC SENSORS AND SYSTEMS ......................................................................74Speed/Timing Sensing Circuit ........................................................................................76Analog Sensors and Circuits...........................................................................................78Engine Mounted Switches ..............................................................................................90Digital Sensors and Circuits............................................................................................92Engine Shutdown Systems..............................................................................................98Ether Injection System..................................................................................................100Demand Fan Controls ...................................................................................................101CAT Data Link..............................................................................................................102Pre-lubrication System..................................................................................................104Logged Events ..............................................................................................................105

    APPLICATION SPECIFIC SYSTEMS..............................................................................107Oil Renewal System......................................................................................................108Wastegate Control .........................................................................................................110

    SLIDE LIST........................................................................................................................112

    SERVICEMAN'S HANDOUTS .........................................................................................114

    STMG 681 - 4 -1/02

  • Major topics

    1

    INTRODUCTION

    This presentation discusses the 3500B Electronic Unit Injection (EUI)Engine Controls used in machi