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SERQ4049April 2004

TECHNICAL PRESENTATION

C7 AND C9 ACERT TECHNOLOGYELECTRONIC ENGINE CONTROLS

Service Training Meeting Guide

SERVICE TRAINING

C7 AND C9 ACERT TECHNOLOGYELECTRONIC ENGINE CONTROLS

AUDIENCE

Level II–Service 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 TruckEngines. 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 TruckEngines.

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 RENR1390-01C-9 CD Cat HI300B Fuel System RENR1392C-9 Engine - Systems and Controls SERH4050

REFERENCES

C7 and C9 On-highway Engines - Troubleshooting Guide SENR9517

Estimated Time: 1 HourIllustrations: 26Handouts: 2Form: Date: 04/04

© 2004 Caterpillar Inc.

TABLE OF CONTENTS

INTRODUCTION TO C7 AND C9 ACERT ELECTRONICS ...................................................5

SYSTEM CALIBRATIONS ........................................................................................................8Injector Trim Calibration .......................................................................................................9Downloading Injector Trim Files ........................................................................................10Calibrating the Injectors ......................................................................................................18

SPEED TIMING SENSOR CALIBRATION ............................................................................26C7 Timing Probe Installation ...............................................................................................27C9 Timing Probe Installation ...............................................................................................29

SMART WASTEGATE .............................................................................................................30

C7 AND C9 ENGINE ECMS ...................................................................................................34

SUPPORT ...................................................................................................................................35

CONCLUSION ..........................................................................................................................36

SERQ4049 - 3 - Text Reference4/04

NOTES


INTRODUCTION TO C7 AND C9 ACERT ELECTRONICS

This presentation will show the principle electronic differences between the existing 3126E andthe C7 ACERT. Also the C-9 and the C9 ACERT. The 3126E and the C-9 have beenredesigned to meet the new U.S. Environmental Protection Agency (EPA) EmissionsRegulations for North America.

ACERT stands for:A AdvancedC CombustionE EmissionR ReductionT 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 providesall the additional functions necessary to service engines with ACERT technology.

1


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-9engine fuel systems. There are many similarities between the existing and the new engines.


3

This presentation will cover the following topics:

- Calibrations:

- Injector trim calibration

- Speed sensor timing calibration

- Smart Wastegate

- Contacts for Caterpillar engine support


4

SYSTEM CALIBRATIONS

There are two calibration routines which will be covered in this presentation:

- Injector Trim Calibration

- Speed Timing Sensor Calibration


5

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 theEPA requirements, the injector must be calibrated. After an injector trim calibration isperformed, each injector will perform within very close limits to each other throughout theoperational envelope or operational speed curve for timing and fuel quantity.

This degree of accuracy is only possible by performing a multiple point calibration. Multiplepoint calibration is only possible with sophisticated calibration data uploaded to the EngineECM.

Prior to ACERT, software maps used to be stored in the Engine ECM. The Engine ECM wouldthen select the correct map using the trim code from the face of the injector. This was typicallya 4 or 6 digit code.

Injector calibration on the ACERT engine is very different from previous engines requiringinjector calibration. The volume of information to be uploaded to the Engine ECM is fargreater than before. This volume precludes the use of simple trim codes normally stamped onthe injector. The trim code, if used, would contain hundreds of characters, which would not bepractical.

In order to accommodate this volume of data, the required information is loaded into an injectortrim file which is uploaded to the Engine ECM.


6

Downloading Injector Trim Files

As with the previous engine, the injectors are calibrated using data in an injector trim file. Thefile is identified by the injector serial number (seen on the following slides). This process issimilar to using WinFlash.

The files are stored and retrieved from SIS (Service Information System). However, theinjector serial number must be obtained first.

Injector trim files are supplied on a CD with their replacement injectors. The CDs are availablefor TEPS dealers.


7

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 case4382.

The four digit random number (injector confirmation code) is applied to the injector (with alaser) and included in the injector trim file. This is a security measure to make sure thetechnician actually has the injector. Cat ET (Electronic Technician) cross checks the injectorserial number and confirmation code in the injector trim file against what is entered into CatET.


1

2

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 becontacted to have the SIS Web profile changed to turn on the "Injector Trim files."


9

Follow the instructions on screen (left arrow) which says: "Please enter valid search criteria tothe right."

Follow the instructions on the right hand side, "Injector Trim File Download" which containsthe box for the serial number (right arrow).


10

Enter the serial number in the box (arrow).


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 inSIS. This information is used by the factory and does not affect replacement or calibration ofinjectors.

NOTE: Currently, only one file can be downloaded at a time.


12

The File Download dialog box will appear:

- Check the radio button: Save the file to Disk

- Click the OK button


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 forcalibration.

NOTE: A folder called "Injector Trim Files" can be created to contain the downloadedtrim files. Cat ET preferences can then be set to automatically look to this folder for thetrim files.


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. Nopasswords are required to perform calibrations.


Note the two buttons Change and Exchange at the bottom of the screen. Both of thesefunctions will be covered during the presentation.

Select the injector to program and click the Change button at the bottom of the screen. In thiscase injector number one is selected. The "Open" dialog box will appear.

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 beautomatically located in the same way as the Flash File folder is located.

15

16


17

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 willdisplay an error message as shown on this slide.


18

A prompt indicates emissions could be affected by an input error.

If Yes is selected, Engine ECM programming will start.


19

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 bedisplayed. The engine will run, but with a warning light.


20

There are times when two injectors may be exchanged for diagnostic purposes. In this case it isnecessary 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 beenadded 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.


21

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 isnumber four.

Select OK.


22

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 therespective injectors. Failure to match the files to the correct injectors may result in a customercomplaint of a roughly running engine.

NOTE: The Trim Files functions described in this section are only possible usingSTW/Cat ET Version 2003B or higher. If a previous version is used, none of thesefunctions can be accessed.


23

SPEED TIMING SENSOR CALIBRATION

There is no change from the existing C-9 Speed/Timing Sensor calibration to the new C9calibration.

The C7 has a major change from the existing 3126E. The probe is moved from the flywheelhousing to the cylinder block.

This change improves the accuracy of the calibration by measuring the angular position on theactual crankshaft. Accuracy is vital in order to meet the new emissions requirements.


24

C7 Timing Probe Installation

As previously mentioned, the C7 Timing Probe is installed in the cylinder block which has asimilar 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.


25

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.


26

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


27

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 iselectronically controlled by the Engine ECM using a solenoid valve and is operatedmechanically using boost for actuation.

The Smart Wastegate Control also modulates boost pressure to prevent cylinder overpressureand turbo overspeed at high engine speed and load while still providing enough cylindercooling at peak torque.

This control also enhances high altitude performance by maintaining boost as the vehicle gainsaltitude.

Boost pressure is modified by bypassing a portion of the engine exhaust around theturbocharger. The amount of exhaust bypass is determined by the position of the wastegatecanister 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 SmartWastegate Control. Bridge engines had improved emissions over the previousproduction engines, but were not able to fully meet the all of the EPA standards.


28

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


29

The wastegate solenoid is actually a modified hydraulic valve. The solenoid operation issimilar to the HEUI hydraulic pump control valve.

A PWM signal from the Engine ECM controls the modulation of the wastegate bypass valve.


30

With the Smart Wastegate Control, boost comes from the intake manifold and passes throughthe wastegate solenoid control valve.

The wastegate solenoid is mounted on the inlet manifold. There is a bleed orifice which allowsthe system to bleed pressure from the wastegate line.

The Engine ECM reads engine speed, load, and actual boost. The Engine ECM compares theseparameters to the desired boost maps and closes the loop to drive actual pressure to meet thedesired pressure.

When the solenoid is de-energized, boost is allowed to enter the wastegate canister and limitpressure. As the Engine ECM sends current to the solenoid, pressure is blocked from themanifold 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).


31

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 andindustrial) ECMs.


32

SUPPORT

For support, technicians are available at the Caterpillar On-Highway Engine Call Center24-hours a day, seven days a week to answer technical questions. Upon calling the 800 numbershown on the slide, a voice menu will direct the caller to the appropriate contact to handle asituation.

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.


33

CONCLUSION

ACERT takes us to the next generation of diesel engines without the necessity of EGR andother maintenance intensive accessories.

In brief, ACERT could be described as sophisticated simplicity. The problems of meeting theemissions standards are met with sophisticated, intelligent software and cutting edge injectorsusing the latest technology. This technology does not result in additional sophistication inmaintenance and repair.


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 theengines 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-passvalve:

True / False

7. A smart wastegate controls or limits the following (directly or indirectly):

a. Turbocharger speedb. Manifold pressurec. Cylinder pressured. Emissionse. High altitude engine performance enhancementf. All of the above

8. ECMs are interchangeable between engines as follows (Choose one answer):

a. Between C7 and C9 ACERT enginesb. Between C-9 and C9 ACERT enginesc. Not interchangeabled. Between C-7 and C7 ACERT engines

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


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 theengines with ACERT Technology? Answer: Slide No. 6 - Injectors are calibrated using afile uploaded to the ECM

2. Trim files are available from what two sources? Answer: Slide No. 6 - Supplied with SISand on a CD with the injector

3. What information is used to identify the trim file? Answer: Slide No. 6 - The injectorserial number

4. The confirmation code is used to: Answer: Slide No. 7 - Reduce the possibility of a serialnumber 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 actuatedvalve is used

7. A smart wastegate controls or limits the following (directly or indirectly):

a. Turbocharger speedb. Manifold pressurec. Cylinder pressured. Emissionse. High altitude engine performance enhancementf. 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. Between C7 and C9 ACERT enginesb. Between C-9 and C9 ACERT enginesc. Not interchangeabled. 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 - AdvancedCombustion Emissions Reduction Technology


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