SERQ4049 April 2004

SERVICE TRAINING
TECHNICAL PRESENTATION

C7 AND C9 ACERT TECHNOLOGY ELECTRONIC ENGINE CONTROLS

Service Training Meeting Guide

C7 AND C9 ACERT TECHNOLOGY ELECTRONIC ENGINE CONTROLS

AUDIENCE
Level IIService personnel who understand the principles of machine systems operation, diagnostic equipment, and procedures for testing and adjusting.

CONTENT
This presentation provides update information on the C7 and C9 ACERT On-highway Truck Engines. This presentation may be used for self-paced and self-directed training.

OBJECTIVES
After learning the information in this presentation, the serviceman will be able to: 1. Locate and identify the new electronic components on the C7 and C9 ACERT Truck Engines. 2. Explain the operation of the new components in the systems. 3. Explain new procedures in testing and adjusting. 4. Identify new tooling.

PREREQUISITES
3126B CD Cat HI300 Fuel System C-9 CD Cat HI300B Fuel System C-9 Engine - Systems and Controls RENR1390-01 RENR1392 SERH4050

REFERENCES
C7 and C9 On-highway Engines - Troubleshooting Guide SENR9517

Estimated Time: 1 Hour Illustrations: 26 Handouts: 2 Form: Date: 04/04

2004 Caterpillar Inc.

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TABLE OF CONTENTS
INTRODUCTION TO C7 AND C9 ACERT ELECTRONICS ...................................................5 SYSTEM CALIBRATIONS ........................................................................................................8 Injector Trim Calibration .......................................................................................................9 Downloading Injector Trim Files ........................................................................................10 Calibrating the Injectors ......................................................................................................18 SPEED TIMING SENSOR CALIBRATION ............................................................................26 C7 Timing Probe Installation ...............................................................................................27 C9 Timing Probe Installation ...............................................................................................29 SMART WASTEGATE .............................................................................................................30 C7 AND C9 ENGINE ECMS ...................................................................................................34 SUPPORT ...................................................................................................................................35 CONCLUSION ..........................................................................................................................36

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NOTES

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INTRODUCTION TO C7 AND C9 ACERT ELECTRONICS This presentation will show the principle electronic differences between the existing 3126E and the C7 ACERT. Also the C-9 and the C9 ACERT. The 3126E and the C-9 have been redesigned to meet the new U.S. Environmental Protection Agency (EPA) Emissions Regulations for North America. ACERT stands for: A Advanced C Combustion E Emission R Reduction T Technology Key new electronic features include: - C7 and C9 injector calibration procedure - C7 Timing calibration procedure - Smart Wastegate NOTE: Caterpillar Electronic Technician (Cat ET) Version 2003B or higher provides all the additional functions necessary to service engines with ACERT technology.

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2 There are prerequisites for this presentation that should be completed in advance. Prerequisite study references: - 3126B CD ROM "HEUI HI300 Fuel System" RENR1390-01 - C-9 CD ROM "HEUI HI300B Fuel System" RENR1392 - C-9 Training Manual "C-9 Engine - Systems and Controls" (CD ROM) SERH4050 The study reference CD ROMs offer a complete description of the existing 3126E and C-9 engine fuel systems. There are many similarities between the existing and the new engines.

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This presentation will cover the following topics: - Calibrations: - Injector trim calibration - Speed sensor timing calibration - Smart Wastegate - Contacts for Caterpillar engine support

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SYSTEM CALIBRATIONS There are two calibration routines which will be covered in this presentation: - Injector Trim Calibration - Speed Timing Sensor Calibration

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Injector Trim Calibration The first of these two system calibrations to be covered is the injector trim calibration. In order to reach the very finely required tolerances in injector performance and to meet the EPA requirements, the injector must be calibrated. After an injector trim calibration is performed, each injector will perform within very close limits to each other throughout the operational envelope or operational speed curve for timing and fuel quantity. This degree of accuracy is only possible by performing a multiple point calibration. Multiple point calibration is only possible with sophisticated calibration data uploaded to the Engine ECM. Prior to ACERT, software maps used to be stored in the Engine ECM. The Engine ECM would then select the correct map using the trim code from the face of the injector. This was typically a 4 or 6 digit code. Injector calibration on the ACERT engine is very different from previous engines requiring injector calibration. The volume of information to be uploaded to the Engine ECM is far greater than before. This volume precludes the use of simple trim codes normally stamped on the injector. The trim code, if used, would contain hundreds of characters, which would not be practical. In order to accommodate this volume of data, the required information is loaded into an injector trim file which is uploaded to the Engine ECM.

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Downloading Injector Trim Files As with the previous engine, the injectors are calibrated using data in an injector trim file. The file is identified by the injector serial number (seen on the following slides). This process is similar to using WinFlash. The files are stored and retrieved from SIS (Service Information System). However, the injector serial number must be obtained first. Injector trim files are supplied on a CD with their replacement injectors. The CDs are available for TEPS dealers.

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The injector serial number is shown above on the injector (1). Also the "Injector Confirmation Code" is to the right of the Serial Number (2), in this case 4382. The four digit random number (injector confirmation code) is applied to the injector (with a laser) and included in the injector trim file. This is a security measure to make sure the technician actually has the injector. Cat ET (Electronic Technician) cross checks the injector serial number and confirmation code in the injector trim file against what is entered into Cat ET.

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8 On the SIS main menu, locate "Injector Trim Files" (arrow). NOTE: If this item is not on the main menu, then the Dealer SIS Coordinator should be contacted to have the SIS Web profile changed to turn on the "Injector Trim files."

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9 Follow the instructions on screen (left arrow) which says: "Please enter valid search criteria to the right." Follow the instructions on the right hand side, "Injector Trim File Download" which contains the box for the serial number (right arrow).

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10 Enter the serial number in the box (arrow).

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11 Click on the Search button to download the file. The file will appear on the left hand side (arrow). Click on this file name to bring up the "File Download" dialog box. The file version number can be ignored when performing the calibration. There is no need to perform an upgrade if the injector file is an earlier version than the file in SIS. This information is used by the factory and does not affect replacement or calibration of injectors. NOTE: Currently, only one file can be downloaded at a time.

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12 The File Download dialog box will appear: - Check the radio button: Save the file to Disk - Click the OK button

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13 Using the "Save As" dialog box: - Click on the folder Injector Trim Files - Click the Open button (opens the folder) - Click the Save button in order to save the file to the PC Once all the files are all downloaded to the PC, they can be uploaded to the Engine ECM for calibration. NOTE: A folder called "Injector Trim Files" can be created to contain the downloaded trim files. Cat ET preferences can then be set to automatically look to this folder for the trim files.

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14 Calibrating the Injectors Open Cat ET and select the following from the Service pull down menu: - Service / Calibrations / Injector Trim Calibration NOTE: Both Dealer and Customer ET can be used to perform this operation. No passwords are required to perform calibrations.

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15

Note the two buttons Change and Exchange at the bottom of the screen. Both of these functions will be covered during the presentation. Select the injector to program and click the Change button at the bottom of the screen. In this case injector number one is selected. The "Open" dialog box will appear.

16

Select (highlight) the file for calibration to copy to the Engine ECM. NOTE: The Cat ET preferences menu allows the Injector Trim Files folder to be automatically located in the same way as the Flash File folder is located.

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Enter the Confirmation Code. This code was recorded from the injector with the serial number. This code ensures that the correct and compatible file is selected a confirmation. Cat ET determines if the Confirmation Code and the file are a valid pair. If not, Cat ET will display an error message as shown on this slide.

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A prompt indicates emissions could be affected by an input error. If Yes is selected, Engine ECM programming will start.

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Upon successful completion, the Injector Serial Number field will have a new value. NOTE: If the Serial Number field has not been programmed, an Active Fault will be displayed. The engine will run, but with a warning light.

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There are times when two injectors may be exchanged for diagnostic purposes. In this case it is necessary that the files are also moved to their respective injector positions. To facilitate this operation and to reduce the risk of an error, a file exchange function has been added to the Injector Trim File Calibration screen. First, highlight the first injector to be exchanged as shown above; in this case number one. Select the Exchange button.

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Select the second injector of the pair to be exchanged: Using the lower "With Injector" box, select the number of the new position. In this case it is number four. Select OK.

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Upon successful completion, both Injector Serial Number fields will have new values. It is recommended that a final check be made to ensure that the correct files are installed for the respective injectors. Failure to match the files to the correct injectors may result in a customer complaint of a roughly running engine. NOTE: The Trim Files functions described in this section are only possible using STW/Cat ET Version 2003B or higher. If a previous version is used, none of these functions can be accessed.

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SPEED TIMING SENSOR CALIBRATION There is no change from the existing C-9 Speed/Timing Sensor calibration to the new C9 calibration. The C7 has a major change from the existing 3126E. The probe is moved from the flywheel housing to the cylinder block. This change improves the accuracy of the calibration by measuring the angular position on the actual crankshaft. Accuracy is vital in order to meet the new emissions requirements.

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C7 Timing Probe Installation As previously mentioned, the C7 Timing Probe is installed in the cylinder block which has a similar installation location to the C9. The following procedure is used to install the probe: - Position crankshaft at TDC - Rotate crankshaft 100 in the normal rotation - Install probe IAW Service Manual The Service Manual procedure should be the final authority for the installation procedure. NOTE: The previous 3126E engine had the probe installed in the flywheel housing.

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This illustration shows the C7 Timing Probe location on the block (arrow). The probe location is behind the breather tube and below and left of the Engine ECM.

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C9 Timing Probe Installation There is no change from the existing C-9 timing probe installation: - Position crankshaft at TDC - Rotate crankshaft in the normal rotation 85 (just less than a right angle) - Install probe IAW (in accordance with) the Service Manual

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SMART WASTEGATE This illustration shows the wastegate canister (right arrow) and the bleed orifice (left arrow) which is in the air line tee. The "smart wastegate" is similar to a mechanical wastegate. This control system is installed primarily for emissions reasons. The smart wastegate is electronically controlled by the Engine ECM using a solenoid valve and is operated mechanically using boost for actuation. The Smart Wastegate Control also modulates boost pressure to prevent cylinder overpressure and turbo overspeed at high engine speed and load while still providing enough cylinder cooling at peak torque. This control also enhances high altitude performance by maintaining boost as the vehicle gains altitude. Boost pressure is modified by bypassing a portion of the engine exhaust around the turbocharger. The amount of exhaust bypass is determined by the position of the wastegate canister linkage. The wastegate canister position is dependent on the pressure to the canister. This pressure is controlled by the wastegate solenoid. NOTE: The system also works just like the October 2002 "bridge" engine Smart Wastegate Control. Bridge engines had improved emissions over the previous production engines, but were not able to fully meet the all of the EPA standards.

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The wastegate solenoid is controlled by the Engine ECM and is used to modulate the wastegate position and therefore manifold pressure.

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The wastegate solenoid is actually a modified hydraulic valve. The solenoid operation is similar to the HEUI hydraulic pump control valve. A PWM signal from the Engine ECM controls the modulation of the wastegate bypass valve.

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With the Smart Wastegate Control, boost comes from the intake manifold and passes through the wastegate solenoid control valve. The wastegate solenoid is mounted on the inlet manifold. There is a bleed orifice which allows the system to bleed pressure from the wastegate line. The Engine ECM reads engine speed, load, and actual boost. The Engine ECM compares these parameters to the desired boost maps and closes the loop to drive actual pressure to meet the desired pressure. When the solenoid is de-energized, boost is allowed to enter the wastegate canister and limit pressure. As the Engine ECM sends current to the solenoid, pressure is blocked from the manifold and is allowed to bleed from the canister through the orifice. Currently all C9 engines are equipped with the Smart Wastegate Control. Only the high horsepower C7 engines have the Smart Wastegate Control (above 186 KW/250 HP).

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C7 AND C9 ENGINE ECMS The Version 9 Engine ECMs used on the C7 and C9 engines are identical. These Engine ECMs are not interchangeable with the earlier 3126E and C-9 (machine and industrial) ECMs.

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SUPPORT For support, technicians are available at the Caterpillar On-Highway Engine Call Center 24-hours a day, seven days a week to answer technical questions. Upon calling the 800 number shown on the slide, a voice menu will direct the caller to the appropriate contact to handle a situation. This phone number should be used for technical assistance with C7 and C9 engines. The e-mail address for the call center is shown above.

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CONCLUSION ACERT takes us to the next generation of diesel engines without the necessity of EGR and other maintenance intensive accessories. In brief, ACERT could be described as sophisticated simplicity. The problems of meeting the emissions standards are met with sophisticated, intelligent software and cutting edge injectors using the latest technology. This technology does not result in additional sophistication in maintenance and repair.

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C7 and C9 ACERT Technology Posttest

Directions: Answer the questions with the appropriate response. 1. What is the key difference between the previous injector calibration procedure and the engines with ACERT Technology? 2. Trim files are available from what two sources? 3. What information is used to identify the trim file? 4. The confirmation code is used to: 5. The C7 timing calibration probe is installed on the flywheel housing: True / False 6. The smart wastegate uses a boost-activated canister to actuate the wastegate by-pass valve: True / False 7. A smart wastegate controls or limits the following (directly or indirectly): a. b. c. d. e. f. Turbocharger speed Manifold pressure Cylinder pressure Emissions High altitude engine performance enhancement All of the above

8. ECMs are interchangeable between engines as follows (Choose one answer): a. b. c. d. Between C7 and C9 ACERT engines Between C-9 and C9 ACERT engines Not interchangeable Between C-7 and C7 ACERT engines

9. The letters for "ACERT" Technology stand for:

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C7 and C9 ACERT Technology Posttest - Answers

Instructor Note: This test can be used in the classroom as a formal test using the student copy. Alternatively, the test can be used informally as a verbal question and answer period. 1. What is the key difference between the previous injector calibration procedure and the engines with ACERT Technology? Answer: Slide No. 6 - Injectors are calibrated using a file uploaded to the ECM 2. Trim files are available from what two sources? Answer: Slide No. 6 - Supplied with SIS and on a CD with the injector 3. What information is used to identify the trim file? Answer: Slide No. 6 - The injector serial number 4. The confirmation code is used to: Answer: Slide No. 7 - Reduce the possibility of a serial number error 5. The C7 timing calibration probe is installed on the flywheel housing: Answer: Slide No. 23 - False; installed on the cylinder block 6. The smart wastegate uses a boost-activated canister to actuate the wastegate by-pass valve: Answer: Slide No. 27 - False; an ECM controlled, solenoid operated, pneumatically actuated valve is used 7. A smart wastegate controls or limits the following (directly or indirectly): a. b. c. d. e. f. Turbocharger speed Manifold pressure Cylinder pressure Emissions High altitude engine performance enhancement All of the above

Answer: Slide No. 27 - f. All of the above 8. ECMs are interchangeable between engines as follows (Choose one answer): a. b. c. d. Between C7 and C9 ACERT engines Between C-9 and C9 ACERT engines Not interchangeable Between C-7 and C7 ACERT engines

Answer: Slide No. 31 - a. Interchangeable between C7 and C9 ACERT engines only 9. The letters for "ACERT" Technology stand for: Answer: Slide No. 1 - Advanced Combustion Emissions Reduction Technology