C-16 Truck Engine W1A00001-UP(SEBP3679 - 39) - Documentation Pagina 1 di 8

Shutdown SIS

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Product: TRUCK ENGINE

Model: C16 TRUCK ENGINE W1A
Configuration: C-16 Truck Engine W1A00001-UP

Systems Operation
C-15, C-16 and C-18 Engines
Media Number -RENR2307-03 Publication Date -01/01/2007 Date Updated -10/01/2007

i02524333

Electronic Control System Components

SMCS - 1900

Illustration 1 g01262602

Typical example

(1) Camshaft position sensor

(2) Boost pressure sensor

(3) Connector for the electronic unit injector P300/J300

(4) Inlet air temperature sensor

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(5) Ground point for the OEM

(6) Engine Control Module (ECM)

(7) Crankshaft position sensor

(8) Fuel temperature sensor

(9) Atmospheric pressure sensor

(10) Engine oil pressure sensor

(11) ECM connector that is for the engine

(12) ECM connector that is for the OEM

Illustration 2 g01262604

Typical example

(13) Coolant temperature sensor

Engine Monitoring
The electronic control system includes Engine Monitoring. The system monitors engine oil pressure, coolant
temperature, inlet manifold air temperature and coolant level. All truck engines are shipped from the factory
with the following sensors: oil pressure sensor, coolant temperature sensor and inlet manifold air temperature.
The OEM is responsible for providing and installing the coolant level sensor. The coolant level sensor is the
only sensor that can be individually selected for Engine Monitoring. The ECM Customer Programmable
Parameter enables the coolant level sensor. The default factory setting is "NO". The ECM Customer
Programmable Parameters have four levels that are for Engine Monitoring:

• OFF

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• Warning (Factory Default)

• Derate

• Shutdown

Engine Monitoring Off Mode

The ECM will ignore the oil pressure sensor and the coolant level sensor. Coolant Temperature is still used
for Cold Mode. Inlet Manifold Air Temperature is used for operation in cold air regardless of the engine
monitoring mode.

"Engine Monitoring Warning Mode"

Warning mode uses the following sensors: Oil Pressure, Coolant Temperature, Inlet Manifold Temperature
and Optional Coolant Level Sensor. Table 2 indicates the diagnostic codes that are available. The table also
shows the effect on engine performance when the diagnostic code is active. When a diagnostic code is active,
the Check Engine Lamp will flash and the Warning Lamp will come on.

Table 1
PID-FMI Description of the Fault Code Warning Lamp Derate
100-01 Low Oil Pressure Warning SOLID NONE
100-11 Very Low Oil Pressure Warning SOLID NONE
105-00 "High Inlet Manifold Air Temperature Warning" SOLID NONE
105-11 "Very High Inlet Manifold Air Temperature Warning" SOLID NONE
110-00 "High Coolant Temperature Warning" SOLID NONE
110-11 "Very High Coolant Temperature" SOLID NONE
111-01 "Low Coolant Level Warning" SOLID NONE
111-11 "Very Low Coolant Level" SOLID NONE

Engine Monitoring Derate and Shutdown Modes

Derate mode and Shutdown mode allow the ECM to alter engine performance in order to avoid damage to the
engine. The engine should return to normal conditions once the problem is corrected. When the engine is
derated, the Check Engine Lamp and the Warning Lamp will flash. Refer to Table 3. In the Derate column,
MPH indicates that the vehicle speed is derated. The maximum derate is 45 mph. HP indicates that the engine
horsepower is limited. The maximum derate is 160 hp. RPM indicates that the engine speed is limited. The
maximum derate is 1350 rpm. For the operating conditions that cause these codes, refer to the appropriate
section for the sensor.

Table 2
PID-FMI Warning Lamp
Description of the Fault Code Derate

100-01 Low Oil Pressure Warning SOLID NONE

MPH, HP, RPM
100-11 Very Low Oil Pressure Warning FLASH

105-00 "High Inlet Manifold Air Temperature Warning" SOLID NONE

"Very High Inlet Manifold Air Temperature
105-11 SOLID NONE
Warning"

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110-00 "High Coolant Temperature Warning" FLASH MPH, HP

110-11 "Very High Coolant Temperature" FLASH MPH, HP
111-01 "Low Coolant Level Warning" SOLID NONE
111-11 "Very Low Coolant Level" FLASH MPH, HP

Engine Monitoring Time to Shutdown

Table 4 indicates the active diagnostic codes that are capable of shutting down the engine when the ECM is
programmed to Shutdown. The "Time To Shutdown" column indicates the amount of time of engine
operation after a diagnostic code is activated. The engine must have been running for at least thirty seconds in
order to activate this mode. The "Start/Restart Time" column indicates the amount of time for engine
operation after start-up if the condition still exists. The "Start/Restart Time" follows a shutdown that is caused
by the "Engine Monitoring" function. A "NO" indicates that the code will not cause a shutdown of the engine.

Table 3
PID-FMI Time To Start and Restart
Description of the Fault Code
Shutdown Time
100-01 Low Oil Pressure Warning NO NO
100-11 Very Low Oil Pressure Warning 30 sec 18 sec
"High Inlet Manifold Air Temperature
105-00 NO NO
Warning"
"Very High Inlet Manifold Air Temperature
105-11 NO NO
Warning"
110-00 "High Coolant Temperature Warning" NO NO
110-11 "Very High Coolant Temperature" 20 sec 60 sec
111-01 "Low Coolant Level Warning" NO NO
111-11 "Very Low Coolant Level" 30 sec 80 sec

Electronic Control System Operation

The fuel delivery and injection timing are electronically controlled. In comparison to engines that are
controlled mechanically, the electronic control system provides increased control of timing and increased
control to the fuel to the air ratio. Injection timing is achieved by precise control of injector firing time, and
engine power is controlled by adjusting the firing duration. The ECM energizes the fuel injection solenoid in
order to start the injection of fuel. The ECM will de-energize the fuel injection solenoid in order to stop the
injection of fuel. Refer to the Systems Operation, "Fuel System" for a complete explanation of the fuel
injection process.

The engine uses the following types of electronic components: input, control and output.

An input component is one that sends an electrical signal to the ECM. The signal that is sent varies in either
voltage or in frequency when there is a change in some specific system of the vehicle. An example would be
the engine speed/timing sensor or the coolant temperature sensor. The ECM sees the input sensor signal as
information about the condition, environment, or operation of the vehicle.

An electronic control system component receives the input signals. Electronic circuits that are inside the
ECM evaluate the signals. The ECM then supplies electrical energy to the output components of the system,
which are in response to predetermined combinations of input signal values.

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An output component is one that is operated by the ECM. An output component receives electrical energy
from the ECM. The electrical energy is used to perform one of the following functions:

• Perform work. An example would be moving a solenoid plunger. An output component takes an active
part in regulating or operating the vehicle.

• An output component can give information or a warning. An example would be a light or an alarm to
the operator of the vehicle or other person.

Output components provide the ability to electronically control the engine operation in order to improve the
following items: performance, fuel consumption rate and reduced emissions levels. A brief description of the
sensors that are used in the electronic control system follows:

Atmospheric Pressure Sensor

The atmospheric pressure sensor is an absolute pressure sensor that measures crankcase pressure. Both the
boost pressure and the oil pressure are communicated to the service tools and over the data link. The two
pressures are calculated by subtracting the reading for the atmospheric pressure sensor. The atmospheric
pressure sensor measures pressure from 0 (0) to 116 kPa (17 psi). The atmospheric pressure sensor is supplied
with + 5 VDC by the ECM.

Boost Pressure Sensor

The boost pressure sensor is an absolute pressure sensor that measures inlet manifold pressure. The difference
between the inlet manifold pressure measurement and the pressure that is measured by the atmospheric
pressure sensor is called the boost pressure. The information is communicated to the service tools and over
the data link. The boost pressure sensor measures pressure from 20 kPa (3 psi) to 472 kPa (68 psi). The boost
pressure sensor is supplied with + 5 VDC by the ECM.

Coolant Level Sensor

The coolant level sensor is installed by the vehicle OEM. The coolant level sensor is an optional sensor. The
coolant level sensor is selected through the ECM Customer Programmable Parameter. The ECM Customer
Programmable Parameters can be protected by Customer Passwords.

Coolant Temperature Sensor

The engine coolant temperature is measured by an electronic sensor that is mounted on the water temperature
regulator housing. The coolant temperature signal is used to modify the engine fueling and the engine timing
for improved cold start and white smoke cleanup. The ECM supplies the coolant temperature sensor with 5.0
± .5 VDC. The sensor output voltage is + 0.5 to + 4.5 VDC. The sensor output voltage depends on the engine
coolant temperature. Coolant temperature is used to indicate the Cold Mode operation and coolant
temperature is used for Engine Monitoring.

Coolant Temperature Engine Monitoring Operation

The Check Engine Lamp will flash if Engine Monitoring is programmed to Derate the engine. The Check
Engine Lamp will flash if Engine Monitoring is programmed to Shut down the engine. The Warning Lamp
will then flash when the associated diagnostic code is active. When the Warning Lamp flashes, the engine is
in Derate Mode.

Fuel Temperature Sensor

The Fuel Temperature is monitored in order to adjust the calculations for the fuel rate. The temperature of the
fuel is also monitored in order to correct the power of the engine. The power of the engine is altered in order
to provide constant power when fuel temperatures exceed 30°C (86°F). The maximum correction of the
power occurs when the fuel temperature reaches 70°C (158°F). Fuel temperature that exceeds 90°C (194°F)
for ten minutes causes a diagnostic code to be logged.

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Inlet Manifold Temperature Sensor

Inlet manifold temperature is used for the cooling fan driver and Engine Monitoring. The inlet manifold
temperature sensor is used in order to warn the driver of an excessive inlet manifold air temperature. When
Engine Monitoring has been programmed to derate the engine, the inlet manifold temperature sensor will not
cause the following events: derate and shutdown.

Before a diagnostic code is logged into the ECM, the inlet manifold air temperature must exceed the
temperatures that are indicated for thirty seconds. A diagnostic code for the High Inlet Manifold Temperature
is triggered at 91°C (195°F). A diagnostic code for the Very High Inlet Manifold Temperature is triggered at
110°C (230°F). Unlike the diagnostic codes that are associated with Engine Monitoring, the codes that are
associated with the inlet manifold air temperature are still available when Engine Monitoring is "OFF". The
Warning Lamp is also turned on if Engine Monitoring is programmed to Warning, Derate, or Shutdown.

Oil Pressure Sensor

The oil pressure sensor is an absolute pressure sensor that measures oil pressure in the oil gallery. The oil
pressure is communicated over the data link and the oil pressure is displayed by the electronic service tool.
The ECM uses the sensor input only if the parameter for Engine Monitoring is programmed to Warning,
Derate, or Shutdown. The oil pressure sensor measures pressure from 0 kPa (0 psi) to 1135 kPa (165 psi). The
sensor is supplied by the ECM with 5 VDC.

Retarder Enable for the Compression Brake

If the engine is equipped with a compression brake, the operation of the compression brake is provided
through the RETARDER enable output. The RETARDER enable status is determined by the ECM. In order
to determine the RETARDER enable status, the following items are monitored by the ECM: dash switch for
the compression brake, clutch switch, accelerator pedal position, cruise control switch and engine speed
(rpm). Operation of the compression brake will be restricted under improper engine operating conditions. The
following conditions must be met in order to enable the compression brake:

• The engine speed (rpm) is above 800 rpm.

• The accelerator pedal position is less than 7 percent.

• The clutch pedal is not depressed.

• The switch for the compression brake is energized.

Camshaft Position Sensor and Crankshaft Position Sensor

The camshaft position sensor and the crankshaft position sensor are used to determine both engine speed and
fuel injection timing. The camshaft position sensor senses motion of the camshaft. The crankshaft position
sensor senses motion of the crankshaft.

Accelerator Pedal Position Sensor

The accelerator pedal position sensor is an electronic sensor that is connected to the accelerator pedal. The
accelerator pedal position sensor sends a Pulse Width Modulated Signal to the ECM.

Vehicle Speed Sensor

The vehicle speed sensor is an electromagnetic pickup that measures vehicle speed. The sensor measures
vehicle speed from the rotation of the gear teeth that are in the drive train of the vehicle.

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Check Engine Lamp (Diagnostic Lamp)

The Check Engine Lamp is sometimes referred to as the Diagnostic Lamp. The Check Engine Lamp is
located on the dashboard of the vehicle. The Check Engine Lamp can be used as a diagnostic lamp in order to
communicate any problems with the operation of the electronic control system.

Note: The Check Engine Lamp and the Warning Lamp are different. For more information about terminology
for electronic components, refer to Systems Operation, "Glossary of Electronic Control Terms".

When a diagnostic fault is detected by the ECM, the Check Engine Lamp will turn ON. When a diagnostic
fault is detected by the ECM, the Check Engine Lamp will blink at five second intervals. The Check Engine
Lamp should be ON and the Check Engine Lamp should be flashing Diagnostic Code 55 whenever the
START switch is turned ON but the engine is not running. This condition will test whether the lamp is
operating correctly.

If the Check Engine Lamp comes ON and the Check Engine Lamp stays ON after the initial start-up, the
system has detected a fault. The Check Engine Lamp or service tools can be used to identify the diagnostic
code.

The dash mounted Cruise Control Switches are used to interrogate the ECM for system status. With the
Cruise Control Switch in the OFF position, move the SET/RESUME switch to the RESUME position. The
Check Engine Lamp will begin to flash in order to indicate a two digit diagnostic code while the
SET/RESUME switch is held in the RESUME position. The sequence of flashes represents the system
diagnostic message. The first sequence of flashes adds up to the first digit of the diagnostic code. After a one
second pause, a second sequence of flashes will occur. The second sequence of flashes represent the second
digit of the diagnostic code. If necessary, additional diagnostic codes will follow after a three second pause.
Additional diagnostic codes will be displayed in the same manner.

The Check Engine Lamp is also used to monitor the Idle Shutdown Timer. The Check Engine Lamp will start
to flash at a rapid rate 90 seconds before the programmed idle time is reached. If the clutch pedal indicates a
change in position or the service brake pedal indicates a change in position during the final 90 seconds, the
idle shutdown timer will be disabled. The idle shutdown timer will then need to be reset.

Engine Control Module

The ECM power supply provides electrical power to all engine mounted sensors and actuators. Reverse
voltage polarity protection and resistance to vehicle power system voltage swings or surges have been
designed into the ECM. The ECM also monitors all input from the sensors. The ECM also provides the
correct outputs in order to ensure desired engine operation.

The ECM contains memory in order to store customer specified parameters. The ECM also identifies a
selected factory engine rating. The memory also contains a personality module identification code in order to
prevent unauthorized tampering. The memory also contains an identification code in order to prevent
switching of engine ratings and other pertinent manufacturing information.

The wiring harness provides communication or signal paths to the various sensors. A boost pressure sensor,
the Data Link Connector, and the engine/vehicle connectors are examples. The ECM performs many
functions. The ECM contains all of the engine performance information. The ECM contains all of the
information for the emission certification. Several examples are listed: engine timing, air/fuel ratio and rated
fuel position control maps.

Note: The list that follows contains a portion of the customer specified parameters: Engine Power Rating,
Vehicle Identification Number, "PTO Vehicle Speed Limit", PTO Engine RPM Limit (PTO RPM), Low Gear
Limit, Intermediate Gear Limit, Engine RPM At Vehicle Speed Limit (ENG RPM At VSL), Geardown
Protection, Top Engine Limit (TEL), Vehicle Speed Limit (VSL), High Gear Turn On Speed, Low Cruise
Control Set Limit (LCC), "High Cruise Control Speed Set Limit", Retarder Coast/Latch and Idle Shutdown
Timer. The customer specified parameters may be secured by customer passwords. An ECM may have all of
the programmed parameters or any combination of the programmed parameters. For a brief explanation of
each of the customer specified parameters, refer to the Troubleshooting Guide.

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The ECM is programmed to run diagnostic tests in order to separate a fault to a specific circuit. Once a fault
is detected, the fault can be displayed in several ways on the dash mounted Check Engine Lamp. The ECM
will log most of the diagnostic codes that are generated during engine operation. The logged codes or the
active codes can be read by an electronic service tool.

Cooling Fan Relay Driver

The ECM provides a cooling fan disable signal. If the ECM output is high, the fan is off. The cooling fan
disable signal is for "ON/OFF" control of the cooling system fan. The "ON/OFF" control is based on the
following items: coolant temperature, engine brake operation, engine speed and inlet manifold air
temperature. The "ON/OFF" control is also based on the OEM installed air conditioning high pressure switch.
All other control of the cooling fan is the responsibility of the OEM.

In order to prevent unnecessary cycling of the cooling fan due to reduced voltage levels during engine
cranking, the ECM turns the fan "OFF". Because an electrical open circuit is the most likely failure mode,
Caterpillar recommends a normally open relay for this circuit.

Copyright 1993 - 2012 Caterpillar Inc. Wed Apr 11 21:20:41 UTC+0200 2012
All Rights Reserved.
Private Network For SIS Licensees.

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