Electronic Control System: Systems Operation

320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0...
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Product: EXCAVATOR
Model: 320 EXCAVATOR YBP
Configuration: 320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine
Systems Operation
C7.1 Engines for Caterpillar Built Machines
Media Number -UENR3387-22 Publication Date -01/07/2015 Date Updated -19/09/2018
i05256690
Electronic Control System

SMCS - 1900
Introduction
The engine is designed for electronic control. The engine has an Electronic Control Module (ECM), a
fuel injection pump and electronic unit injectors. All of these items are electronically controlled.
There are also a number of engine sensors. The engine is equipped with an electronically controlled
wastegate for the turbocharger. The ECM controls the engine operating parameters through the
software within the ECM and the inputs from the various sensors. The software contains parameters
that control the engine operation. The parameters include all of the operating maps and customer-
selected parameters.
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Illustration 1 g03347120
Typical example
(1) Air cleaner
(2) Air inlet temperature sensor
(3) Turbocharger
(4) Wastegate regulator
(5) Engine
(6) Coolant temperature sensor
(7) Air-to-air aftercooler
(8) Crankshaft speed/timing sensor
(9) Electronic unit injectors
(10) Solenoid for the fuel injection pump
(11) Camshaft speed/timing sensor
(12) Fuel injection pump
(13) Fuel transfer pump
(14) Fuel priming pump
(15) Primary fuel filter
(16) Fuel pressure sensor
(17) Oil pressure sensor
(18) ECM
(19) Inlet manifold pressure sensor
(20) Inlet manifold air temperature sensor
(21) Secondary fuel filter
(22) Fuel tank
The electronic control system has the following components:
• ECM
• Pressure sensor
• Temperature sensors
• Crankshaft speed/timing sensor
• Camshaft speed/timing sensor
• The solenoid for the fuel injection pump
• Wastegate solenoid
• Electronic unit injectors
Sensor Locations for the Engine

The illustrations in this section show the typical locations of the sensors for the industrial engine.
Specific engines may appear different from the illustration due to differences in applications.
Typical example of sensor locations on the left side of the engine
(3) Boost pressure sensor
(4) Inlet manifold temperature sensor
(7) Primary speed/timing sensor
(9) Electronic Control Module (ECM)
Typical example of close up views of sensor locations on the left side of the engine
(3) Boost pressure sensor
(4) Inlet manifold temperature sensor
(7) Primary speed/timing sensor
(9) Electronic Control Module (ECM)
Typical example of sensor locations on the right side and top of the engine
(10) Secondary speed/timing sensor
ECM
Typical example
The Electronic Control Module (ECM) (1) functions as a governor and a computer for the fuel
system. The ECM receives signals from the sensors in order to control the timing and the engine
speed.
The electronic system consists of the ECM, the engine sensors, and inputs from the parent machine.
The ECM is the computer. The personality module is the software for the computer. The personality
module contains the operating maps. The operating maps define the following characteristics of the
engine:
• Engine rating
• Torque curves
• High and low idle speed (rpm)
• Emissions
• Injection timing
The factory passwords restrict changes to authorized personnel. Factory passwords are required to
clear any event code. Refer to Troubleshooting, "Factory Passwords" for more information on the
passwords.
The ECM has an excellent record of reliability. Any problems in the system are most likely to be the
connectors and the wiring harness. The ECM should be the last item in troubleshooting the engine.
The programmable software contains all the fuel setting information. The information determines the
engine performance.
Flash programming is the method of programming or updating the programmable software. Refer to
Troubleshooting, "Flash Programming" for the instructions on the flash programming of the
programmable software.
The ECM is sealed and the ECM needs no routine adjustment or maintenance.
Engine Speed
The electronic controls determine the injection timing, the amount of fuel that is delivered to the
cylinders and the intake manifold pressure via the electronically controlled wastegate. These decisions
are based on the actual conditions and the desired conditions at any given time.
The ECM has software that compares the desired engine speed to the actual engine speed. The actual
engine speed is determined through the crankshaft speed/timing sensor and the camshaft speed/timing
sensor. If the desired engine speed is greater than the actual engine speed, the ECM will instruct the
electronic unit injector to inject more fuel in order to increase engine speed.
Timing Considerations
Once the ECM has determined the amount of fuel that is required, the software must determine the
timing of the fuel injection. Fuel injection timing is determined by the ECM after considering input
from the following components:
• Engine coolant temperature sensor
• The sensor for the intake manifold air temperature
• The sensor for the intake manifold pressure
At start-up, the ECM determines the top center position of the number 1 cylinder from the secondary
speed/timing sensor on the camshaft. The ECM decides when fuel injection should occur relative to
the top center position. The ECM optimizes engine performance by control of each of the electronic
unit injectors so that the required amount of fuel is injected at the precise point of the engine's cycle.
The electronic unit injectors are supplied high-pressure fuel from the fuel manifold. The ECM also
provides the signal to the solenoid in the fuel injection pump. The solenoid in the fuel injection pump
controls a valve in the fuel injection pump. This valve controls the volume of fuel that enters the
plungers. By controlling the volume of fuel that enters the plungers, this controls the pressure in the
fuel manifold. Fuel that is not required for the engine is diverted away from the fuel injection pump
back to the fuel tank.
The ECM adjusts injection timing and fuel pressure for the best engine performance, the best fuel
economy, and the best control of exhaust emissions. The actual timing can be viewed with an
electronic service tool. Also, the desired timing can be viewed with an electronic service tool.
Fuel Injection
The programmable software inside the ECM sets certain limits on the amount of fuel that can be
injected.
The Fuel Ratio Control (FRC) Limit is a limit that is based on intake manifold air pressure and engine
rpm. The FRC Limit is used to control the air/fuel ratio in order to control the engine's exhaust
emissions. When the ECM senses a higher intake manifold air pressure, the ECM increases the FRC
Limit. A higher intake manifold air pressure indicates that there is more air in the cylinder. When the
ECM increases the FRC Limit, the ECM allows more fuel into the cylinder.
The Rated Fuel Limit is a limit that is based on the power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and torque outputs to conform to the power and
torque curves of a specific engine model.
These limits are in the programmable software and these limits cannot be changed.
The ECM controls the following characteristics:
• Boost pressure
Diagnostic Codes
When the ECM detects an electronic system problem, the ECM generates a diagnostic code. Also, the
ECM logs the diagnostic code in order to indicate the time of the problem's occurrence. The ECM
also logs the number of occurrences of the problem. Diagnostic codes are provided in order to
indicate that the ECM has detected an electrical problem or an electronic problem with the engine
control system. In some cases, the engine performance can be affected when the condition that is
causing the code exists.
If the operator indicates that a performance problem occurs, the diagnostic code may indicate the
cause of the problem. Use a laptop computer to access the diagnostic codes. The problem should then
be corrected.
Event Codes
Event Codes are used to indicate that the ECM has detected an abnormal engine operating condition.
The ECM will log the occurrence of the event code. This does not indicate an electrical malfunction
or an electronic malfunction. If the temperature of the coolant in the engine is higher than the
permitted limit, then the ECM will detect the condition. The ECM will then log an event code for the
condition.
Passwords
System Configuration Parameters are protected by factory passwords. This will prevent unauthorized
reprogramming of the system and the unauthorized removal of logged events. Factory passwords are
calculated on a computer system that is available only to Caterpillar dealers. Since factory passwords
contain alpha-numeric characters, only an electronic service tool may change System Configuration
Parameters. System Configuration Parameters affect the power rating or the emissions. Passwords
also allow the customer to control certain programmable engine parameters.
Refer to Troubleshooting, "Programming Parameters" and Troubleshooting, "Factory Passwords".
Speed/Timing Sensors
Typical example
The primary speed/timing sensor is located on the left-hand side of the cylinder block close to the
flywheel housing. The primary speed/timing sensor generates a signal by detecting the movement of
the teeth that are located on the crankshaft timing ring (1). The signal that is generated by the
speed/timing sensor is transmitted to the ECM. The ECM uses the signal from the speed/timing sensor
to calculate the position of the crankshaft. The signal is also used to determine the engine speed.
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 -... Page 10 of 12
Typical example
The secondary speed/timing sensor is located on the right-hand side of the cylinder block toward the
rear of the engine. The secondary speed/timing sensor generates a signal that is related to the camshaft
position. The secondary speed/timing sensor detects the movement of the teeth on the timing ring (2)
for the camshaft. The signal that is generated by the speed/timing sensor is transmitted to the ECM.
The ECM calculates the speed and the rotational position of the engine by using the signal. The
secondary speed/timing sensor is required for starting purposes.
Schematic for the speed/timing sensor
When the engine is cranking, the ECM uses the signal from the speed/timing sensor on the camshaft.
When the engine is running the ECM uses the signal from the speed/timing sensor on the crankshaft.
This speed/timing sensor is the primary source of the engine position.
Pressure Sensors
Schematic for the pressure sensors
The boost pressure sensor and the engine oil pressure sensor are active sensors.
The boost pressure sensor provides the ECM with a measurement of inlet manifold pressure in order
to control the air/fuel ratio. This will reduce the engine smoke during transient conditions.
The operating range of the boost pressure sensors is 39 to 400 kPa (6 to 58 psi).
The engine oil pressure sensor provides the ECM with a measurement of engine oil pressure. The
ECM can warn the operator of possible conditions that can damage the engine. This includes the
detection of an oil filter that is blocked.
The operating range for the engine oil pressure sensor ... 13 to 1200 kPa (2 to 174 psi)
Temperature Sensors
Schematic for the engine temperature sensors
The air inlet temperature sensor and the coolant temperature sensor are passive sensors. Each sensor
provides a temperature input to the ECM. The ECM controls following operations:
• Fuel delivery
• Injection timing
The operating range for the sensors ... −40° to 125°C (−40° to 257°F)
The sensors are also used for engine monitoring.
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320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0...

Electronic Control System

The electronic control system has the following components:

• Crankshaft speed/timing sensor

• Camshaft speed/timing sensor

• The solenoid for the fuel injection pump

• Electronic unit injectors

Sensor Locations for the Engine

• High and low idle speed (rpm)

• Engine coolant temperature sensor

• The sensor for the intake manifold air temperature

• The sensor for the intake manifold pressure

The ECM controls the following characteristics:

Refer to Troubleshooting, "Programming Parameters" and Troubleshooting, "Factory Passwords".

The sensors are also used for engine monitoring.

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