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1
SERQ4108_tier 2 electronics
3054/6E Versions
"C" and "E" versions are Tier 2 emissions compliant
"C" version represents mechanically governed
"E" version represents electronic controls
3054E is a 3054C but with an electronically controlled injection system
3056E is basically a 3056 type 2 with an electronically controlled
injection system
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
The harness is mechanically fixed to the engine via clips to keep the
it secure and away from potential damage.
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SERQ4108_tier 2 electronics
Electronic Components
VP30 Electronic
Distributor
Pump
Machine Interface
Connector
Voltage Load
Protection Module
Diagnostic
Connector
A4 E1
36-1
Tooth
Crank Gear
Speed/
Position
Sensor
Intake Manifold
Pressure
Sensor
Engine Oil
Pressure
Sensor
Electroni
c Service
Tool
Intake Manifold
Temperature Sensor
Engine Coolant
Temperature Sensor
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SERQ4108_tier 2 electronics
For early pumps without 12v or 24V identification, the following numbers
stamped on the side of the pump body can be used
12V = 2644P502, T/TA 2644N204, NA 2644N205
24V= 2644P501, T/TA 2644N401
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SERQ4108_tier 2 electronics
4 Cylinder Timed at
TDC
- Pin Crankshaft
- Pin Pump
6 Cylinder Timed at
4 degrees after TDC
- Use special tool to
locate 4 degrees
- Pin Pump
The VP30 pump needs to be pin timed to lock it in the correct position before
fitting it to the engine.
The engine must also be set to the correct position. This set position is
different between the 3054E and 3056E.
The 3054E should be set at TDC, compression number one using pin 2306283. (Same as 3054C/C4.4).
The 3056E should be set at 4 degrees after TDC compression number one
using tool 226-2270 in number two injector hole.
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SERQ4108_tier 2 electronics
Fuel Quantity
control valve
Speed/timing
sensor
Cam plate and roller cage: Provides the plunger motion needed to
produce high pressure fuel.
Fuel quantity control valve: Opens and closes fuel passages and
controls the injected fuel quantity.
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SERQ4108_tier 2 electronics
VP30 Components
Pump ECM
Fuel Temp
Sensor
Fuel Control
Solenoid
Timing
advance unit
Timing control
solenoid
VP30 COMPONENTS
Other individual components of the Bosch VP30 fuel injection pump are shown in
this illustration. The components and their functions are briefly described below:
-
Timing advance unit: Changes the mechanical position of the roller cage to
alter the injection timing.
Fuel control solenoid: Converts electrical signals from the pump control
module into mechanical motion.
Pump ECM: The electronic brain of the VP30 pump that interfaces with the
Caterpillar ADEM4 control unit.
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SERQ4108_tier 2 electronics
Plunger rotating
& moving
backwards.
Electronic
supply to
Solenoid Coil
from ECM (Off)
0v (off)
Time
Pressurization
Chamber filling
with fuel.
Output to Injectors.
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SERQ4108_tier 2 electronics
Pump Injecting
Fuel Return
Plunger rotating
& moving
forwards
Fuel Quantity
Solenoid
energized
(valve closed)
Electronic
supply to
Solenoid Coil
from ECM (On)
Time
Output to Injectors,
injecting fuel
Pressurization
Chamber filled
with fuel
PUMP INJECTING
As the pump driveshaft continues to rotate, the cam plate rolls up over the
rollers in the roller cage, causing the pumping plunger to move to the right. The
electronic control module energizes the fuel quantity solenoid, which then
closes the fuel quantity control valve. Fuel is now trapped inside the pumping
chamber and as the pumping plunger continues to move to the right, the fuel
pressure begins to increase.
Pressurized fuel is routed to the proper injector through passages inside the
pump and high pressure fuel is sprayed out of the injector nozzle into the
combustion chamber. When the electronic control module has determined that
enough fuel has been injected, the fuel quantity solenoid is de-energized. Deenergizing the solenoid opens the fuel quantity control valve causing the fuel
pressure inside the pumping chamber to drop and the injection to end.
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SERQ4108_tier 2 electronics
Advanced Timing
Fuel In (Fed from
Lift Pump).
Toothed wheel.
Pressure Relief
Valve.
Transfer Pump.
(Fuel Pressure
inside pump up
to 12 Bar)
Spring return
mechanism.
RET
ADV
PWM signal to
Solenoid from ECM
ADVANCED TIMING
A PWM solenoid is used to control the timing advance unit of the VP30
injection pump. The interior of the VP30 pump is pressurized by the internal
transfer pump that is located in the base of the VP30 housing. Interior pressure
is directly proportional to the injection pump rotational speed. Housing
pressure is routed to the timing piston and forces the piston to move against
spring pressure.
Pressure to the timing piston is controlled via the PWM solenoid actuated valve
located on the timing piston housing. By constantly varying the pressure to the
timing piston, the electronic control module can vary the fuel injection timing.
The inset on this illustration depicts a PWM signal with a low ON time (10%)
which results in increased pressure on the timing piston and an advance in
timing.
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SERQ4108_tier 2 electronics
Retarded Timing
Fuel In (Fed from
Lift Pump)
Toothed wheel
Pressure Relief
Valve
Transfer Pump
(Fuel Pressure
inside pump up
to 12 Bar)
Spring return
mechanism
RET
ADV
PWM signal to
Solenoid from ECM
RETARDED TIMING
Increasing the ON time to the timing control solenoid results in an increase in
effective voltage and allows the solenoid to reduce the pressure to the timing
piston. When the pressure on the timing piston is reduced, the spring then
moves the timing piston to the retard position.
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SERQ4108_tier 2 electronics
V.L.P.M.
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SERQ4108_tier 2 electronics
+BAT Pump
(Pin 7 Pump)
Suppressor &
Filter Circuit
VLPM
Connector
Load
Dump
4
3
-BAT Machine
(Pin 58 MIC)
-BAT Pump
(Pin 6 Pump)
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
CONTROL
OUTPUTS
ECM
Indicator lights
Cables/
Connectors
Switches &
Pushbuttons
Cables/
Connectors
Power Supply,
12 v or 24 v
Computer
Hardware
+
Software
Sensor Power
Supply
Cables/
Connectors
Actuators/
Solenoids
Cables/
Connectors
Relays
Cat
Data
Link
Controller
Area
Network
BASIC SYSTEM
The ADEM4 ECM receives inputs from various switches, sensors and power
supplies via the wiring harness. Inside the ECM, software programs
calculate the required output to relays, solenoid actuators, and indicator
lights to achieve the desired engine response.
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SERQ4108_tier 2 electronics
CONTROL
Digital
PROCESSOR
Analog
PWM
(Pulse Width
Modulated)
Cables/
Connectors
Cables/
Connectors
Power Supply,
12 v or 24 v
MEMORY
(Engine
Program)
Power Supply
for 5 volt
8 volts and
12 volts
CDL
CAN
Electronic
Service
Tool
Fuel
Pump
OUTPUTS
Digital Voltage
Cables/
Connectors
Cables/
Connectors
PWM
(Pulse Width
Modulation)
BASIC SYSTEM
The ADEM4 ECM is designed using a Motorola MPC555 32 bit
microprocessor running at 40 MHz with 22K bytes of read only memory
(RAM) and 448K bytes of flash memory. Voltage outputs of the ADEM4
ECM are:
-
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SERQ4108_tier 2 electronics
ECM Voltages
z Nominal
z
z 18-32
Note these voltage ranges only apply to the ECM not the VP30 fuel pump
ECM VOLTAGES
The same ADEM4 ECM hardware is used for both 12 and 24 volt systems and
has a maximum voltage limit of 48 volts for 2 minutes at 25 degrees C (77
degrees F). Typical current draw of the ADEM4 is 4 amps which does not
include the power supply to the electronic fuel pump. The maximum operating
temperature of the ADEM4 is 110 degrees C (230 degrees F) and the minimum
operating temperature is -40 degrees C (-40 degrees F). When the ignition is
OFF and the ECM is in sleep mode, the maximum current draw is 8mA for a 12
volt ECM and 10mA for a 24 volt ECM.
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SERQ4108_tier 2 electronics
ECM Grounding
z
Grounding
Always ensure the ground strap on the ECM is
connected to the engine block to prevent
Electro Magnetic Interference (EMI).
WARNING!
When carrying out welding or
electrostatic paint spraying, special
precautions should always be
followed.
Global Manpower Development
Page 20
Caterpillar Confidential: Green
ECM GROUNDING
If welding is to be performed on the machine, special precautions need to be
taken to protect the ECM. Always turn off the engine and disconnect the
negative cable from the battery terminal. Place the welding ground cable close
to the welding point. If welding is to be performed on the engine, disconnect
and remove the ECM entirely.
If the machine or engine is to have electrostatic paint applied, remove the ECM
from the engine. If the ECM cannot be removed, connect all 70 pins of the
machine interface connector (MIC) directly to the spray booth ground and
connect two points on the engine block to the same ground. Jump starting the
engine can cause higher voltages (example: jump starting a 12 volt engine with
a 24 volt battery) so care must be taken that voltages do not exceed the ECM
maximum.
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SERQ4108_tier 2 electronics
z
z
High reliability.
External connectors most vulnerable: Bent Pins, over tightened plug
etc.
No serviceable parts.
Never replace an ECM without first connecting ET and carrying out
basic diagnostic checks.
The ECM is the LAST component you should suspect.
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SERQ4108_tier 2 electronics
SENSOR COMMON
P1 J1
INTAKE MANIFOLD
PRESSURE SENSOR
SENSOR COMMON
ECM
L730 (OR)
26
994 (GY)
X731 (BU)
24
14
995 (BU)
15
32
34
J200 P200
J100 P100
ENGINE COOLANT
TEMPERATURE SENSOR
1
2
J103 P103
INTAKE MANIFOLD
TEMPERATURE SENSOR
C967 (BU)
SENSOR COMMON
L731 (BR)
J401 P401
CRANKSHAFT POSITION +
CRANKSHAFT POSITION -
E966 (YL)
E965 (BU)
41
49
CRANKSHAFT POSITION +
CRANKSHAFT POSITION -
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SERQ4108_tier 2 electronics
Temperature Sensors
z
TEMPERATURE SENSORS
The cold start strategies for the 3054E and 3056E engines are the same.
When either the coolant temperature or inlet manifold temperature is measured
at a value of -5 deg. C (23 deg F) or below for more than 0.5 seconds, the glow
plugs will operate when the ignition is turned to the ON position. With the glow
plugs on, a "Wait to Start" lamp will be activated by the ECM for a period of 20
seconds. Once the 20 second period has elapsed the lamp will turn OFF. The
glow plugs will continue to be active however until the engine speed reaches 60
RPM for 2 seconds or more.
Once engine speed reaches 60 RPM for 2 seconds or more, the glow plugs will
turn OFF and the ECM will set minimum engine speed to 1200 RPM for 50
seconds. When the 50 second period has elapsed, engine speed will return to
the low idle value specified within the service tool configuration screen. During
the preheat period if the coolant AND inlet manifold air temperature exceeds -5
deg. C (23 deg F) for more than 0.5 seconds, the "Wait to Start" lamp will turn
off as will the glow plugs.
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SERQ4108_tier 2 electronics
Temperature Sensors
z Thermistor
Ground
Pin No 2
Signal
Pin No 1
TEMPERATURE SENSORS
Temperature sensors are two wire, passive sensors.
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SERQ4108_tier 2 electronics
Temperature Sensors
z
z
z
TEMPERATURE SENSORS
The illustration shows a passive sensor that has been cut-away to show the
internal components.
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SERQ4108_tier 2 electronics
TEMPERATURE
SENSOR
ECM
R1
ANALOGUE TO
Signal
DIGITAL
PROCESSOR
CONVERTER
R2
0 VOLTS
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SERQ4108_tier 2 electronics
Pressure Sensors
A (5 Volts)
C (Signal)
INTAKE MANIFOLD
PRESSURE SENSOR
TEMPERATURE SENSORS
Pressure sensors are active sensors. An active sensor has three wires while a
passive sensor has two wires.
Intake Manifold Pressure Sensor:
-
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SERQ4108_tier 2 electronics
Pressure Sensors
z
Integrated circuit.
Capacitive sensor.
TEMPERATURE SENSORS
Three wire active sensors are more complex internally than two wire passive
sensors.
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SERQ4108_tier 2 electronics
+12V
+12V
Analogue
to
ANALOGUE TO
DIGITAL
Digital
CONVERTER
Converter
Processor
MICROPROCESSOR
0 Volts
0 VOLTS
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SERQ4108_tier 2 electronics
Speed/Position Sensors
z
SPEED/POSITION SENSORS
There are two speed sensors on 3054E and 3056E.
-
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SERQ4108_tier 2 electronics
Crankshaft Sensor
z
z
z
z
CRANKSHAFT SENSOR
Key points on the crankshaft sensor:
-
ECM uses this sensor after it is producing a signal of more than 0.4v
Peak-Peak. (About 300-400 rpm)
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SERQ4108_tier 2 electronics
Crankshaft Sensor
z
CRANKSHAFT SENSOR
The primary engine position information is sensed using a passive speed
sensor (crank shaft speed/position sensor) picking up teeth on a toothed wheel
located on the crankshaft.
The crankshaft mounted toothed wheel has 36 equally spaced teeth, one of
which has been removed. The missing tooth is orientated such that it is read
40 degrees after TDC on the six cylinder engine and 70 degrees after TDC on
the four cylinder engine. The signal generated by this sensor is converted into
speed and engine position information in the ECM, allowing accurate timing
control.
During cranking, the ECM uses the signal from the fuel pump speed sensor to
read engine speed and position. After the engine has started, the ECM uses
the signal from the crankshaft speed/position sensor as the primary source of
engine position.
There are 10 degrees, between each tooth, and 20 degrees where there is no
tooth.
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SERQ4108_tier 2 electronics
Crankshaft Sensor
Slower Speed
Amplitude
(Voltage)
Frequency / Time
Higher Speed
Amplitude
(Voltage)
Frequency / Time
CRANKSHAFT SENSOR
The illustration shows the signal which is produced from the crankshaft speed
and position sensor. This type of signal is called a Sine Wave and alternates
between a positive and negative voltage. In the case of crankshaft speed
sensor, the amplitude or voltage increases and the frequency increases as the
speed of the engine rises.
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SERQ4108_tier 2 electronics
Crankshaft Sensor
CRANKSHAFT SENSOR
The toothed wheel for the primary speed/timing sensor is housed within the
crankcase where it is protected from damage.
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SERQ4108_tier 2 electronics
Crankshaft Sensor
Speed and timing
sensor Sensor
Braided Harness
Harness Clamp
CRANKSHAFT SENSOR
The only visible external component of the primary speed/timing sensor is the
wiring harness connection.
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
Slower Speed
Frequency / Time
On
Off
Higher Speed
Frequency / Time
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
Fault Conditions
-
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SERQ4108_tier 2 electronics
Application Wiring
APPLICATION WIRING
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SERQ4108_tier 2 electronics
42
25A
48
Pump Power
5A
3A
56
+ ECM Supply
57
+ ECM Supply
70
Ignition
58
Ground
69
Ground
68
Ground
Ignition Switch
Start Switch
STARTER
MOTOR
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
System Outputs
SYSTEM OUTPUTS
System outputs are defined as signals that the ECM supplies based on the
inputs it receives.
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SERQ4108_tier 2 electronics
Output Devices
Relays
- Fuel Pump power control
- Start aids
- Electric lift pump (1104 only)
z Lamps
- Engine stop
- Warning / Cold start
z Gauges (PWM)
- Coolant temperature
- Oil pressure
z
OUTPUT DEVICES
Output devices that receive signals from the ECM perform a multitude of
functions. Relays can be energized to control items such as glow plugs and
electric lift pumps. Warning lamps can alert the operator to dangerous engine
conditions. Gauges keep the operator informed about the status of assorted
engine parameters such as oil pressure and coolant temperature.
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SERQ4108_tier 2 electronics
ECM CONNECTOR
43
FUSE
Start
Aid
12 AND 24 VOLT OPTIONS SHOWN
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SERQ4108_tier 2 electronics
3A
Electric lift
pump relay
31
20A
To electric
lift pump
Battery +
MIC CONNECTOR
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
Validation
Switch Needed
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SERQ4108_tier 2 electronics
Throttle Characteristics
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SERQ4108_tier 2 electronics
Dia
g
. li
it
Throttle Characteristics
lim
s.
po
its
ne
zo
ad
De
Limits of potentiometer
Diagnostic Limits.
In an analogue throttle, if a we try to measure values too close to the supply voltage (5V) or to ground (0V) then it
is possible that short circuit, open circuits or noise events will be mistaken for valid signals.
In a PWM throttle, we cannot go as low as 0% or as high as 100% pulse width as both of these would be the same
as no signal, or the full 8 volts.
If the ECM measures values close to 0% or 100% raw signal then it is considered as a sensor fault and a
diagnostic code is sent or logged.
Example; 91-3, (Signal Voltage above normal or shorted to a higher voltage)
Example; 774-4, (Signal Voltage below normal or shorted to a lower voltage)
Position Limits.
A throttle pedal is designed so that when it is in the released position it will give a voltage output of approximately 1
volt. The sensor (potentiometer) used has a tolerance of 1% of full travel. The manufacturing tolerances of the
pedal add a further 2% (of full travel) tolerance.
Pedals will be produced, therefore, which, when in the released position will give a voltage somewhere between
0.7 volts and 1.3 volt
For this pedal the ECM would be configured to give an initial lower position of 15% (equivalent to 1.3V) and a lower
position limit of 10% (equivalent to 0.7V)
If a throttle pedal leaves the production line that gives an output of 1 volt, (when back). Then when the ignition is
turned on the ECM will see that this value is lower than the initial lower limit but greater than the lower position
limit. It will now auto-calibrate to take 1volt to be the lower pedal position.
Dead Zone.
The lower Dead Zone will be a certain amount of throttle movement before the engine speed starts to rise.
The Dead Zone is defined as a percentage of the raw signal. If the throttle auto calibrates then the Dead Zone will
also move.
Upper Diagnostic Limit, Initial Upper Position, Upper Position Limit and Upper Deadzone are defined in exactly the
same way as the lower ones
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SERQ4108_tier 2 electronics
10
20
Switch
Closed (on)
Min Off
Threshold
30
40
50
60
70
80
90
100%
Max On
Threshold
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SERQ4108_tier 2 electronics
10
20
Switch
Closed (on)
30
40
50
60
70
80
90
100%
Min Off
Threshold
z Between
Between Min OFF and Max ON Thresholds When the ECM reads a raw
signal higher than Min OFF but lower than Max ON, it does not care what the
switch position is. This zone is to allow for tolerance of components.
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SERQ4108_tier 2 electronics
10
20
Switch
Closed (on)
30
40
50
60
70
80
90
100%
Min Off
Threshold
Max On
Threshold
Machine Interface Connection
37
37
0 Volts
Not Used
IVS
22
36
0 Volts
12 Volts
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SERQ4108_tier 2 electronics
Multi-Position Switch
MULTI-POSITION SWITCH
The 3054E/3056E electronic control unit may also be configured for a second
throttle. One of the second throttle options can be a multi-position switch to
control engine speed.
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SERQ4108_tier 2 electronics
Throttle
Switch Input
3
Open
Open
Open
Open
Closed
Closed
Closed
Closed
Open
Open
Throttle
Switch Input
2
Open
Open
Closed
Closed
Open
Open
Closed
Closed
Open
Open
Throttle
Switch Input
1
Open
Closed
Open
Closed
Open
Closed
Open
Closed
Open
Closed
Throttle
Switch
Position
1
2
3
4
5
6
7
8
9
10
Valid
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Desired
Engine
Speed
idle
1000
1200
1250
1400
1650
1670
2000
2100
2200
MULTI-POSITION SWITCH
This illustration provides an example of how a multi-position switch might be
used in a real world application. In this example the engine might be used to
drive a stationary pump to provide irrigation water. Changing the engine speed
changes the water flow. Setting the switches in the required position gives the
desired output speed and water flow.
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SERQ4108_tier 2 electronics
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SERQ4108_tier 2 electronics
Indicator Lamps
z
Each flash will have a duration of 0.5 sec followed by 0.3 sec
off.
The lamp will remain of for 2 sec between each digit of the
code.
The lamp will remain off for 5 sec between each fault code.
INDICATOR LAMPS
Table Showing the conversion from flash code to Circuit Identifier (CID).
41
91
100
102
105
110
174
247
253
262
320
342
774
1684
1743
1894
1895
517
154
157
135
133
168
165
514
416
516
141
142
155
158
144
427
428
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SERQ4108_tier 2 electronics
Indicator Lamps
(Time shown in Second)
Lamp On
Lamp Off
INDICATOR LAMPS
The red and yellow indicator lamps are used to display the flash codes. The
indicator lamps may not be present depending on the application, however the
capability to drive them is present within the ADEM4 ECM. If there are no
indicator lamps available, the lamp outputs can be accessed at pins 23 (red
lamp) and 12 (yellow lamp) of the ECM. This illustration shows three different
indicator lamp flash code outputs.
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SERQ4108_tier 2 electronics
Quiz
1. Between which pins on the Engine ECM would there be continuity for the
two 5 volt reference power supplies?
2. What can result from shutting down the engine by means other that using
the ignition switch?
4. How much resistance can be applied to the VP30 pump power supply
before the engine will not start?
5. To correctly pin time the VP30 pump on a 3056E, what position should
number one piston be at ?
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