Caterpillar C4 4 C6 6 amp C7 1 Tier 4 Interim Series

Caterpillar C4 4 C6 6 Amp C7 1 Tier 4 Interim Series-Free PDF

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Electrical Electronic A I Guide Tier 4 Interim C4 4 C7 1 Product Range. 1 0 INTRODUCTION AND PURPOSE 9,1 1 APPLICABLE ENGINES 9. 1 2 ELECTRONIC APPLICATIONS CONTACTS 9,1 3 SAFETY 9. 1 3 1 Warning Welding 10,1 3 2 Warning Electrostatic Paint Spraying 10. 1 3 3 Warning Jump Starting 10,2 0 ENGINE AFTERTREATMENT COMPONENT OVERVIEW 11. 2 1 MAIN ENGINE SENSOR AND ACTUATOR DETAILS 11,2 1 1 Electronic Control Module ECM 12.
2 1 2 Fuel System 12,2 1 3 Engine Speed 12,2 1 4 Core Engine System 13. 2 1 5 NRS Nox Reduction System 13,2 1 6 Air System 14. 2 1 7 Emissions System Assist Devices 14, 2 2 AFTERTREATMENT SYSTEM SENSOR ACTUATOR DETAILS 15. 2 2 1 ARD Auxiliary Regeneration Device System 15,2 2 2 DPF System 15. 2 3 SYSTEM COMPONENT DIAGRAMS AND SCHEMATICS 17, 2 3 1 C4 4 Factory Installed Wiring and Components 17.
2 3 2 C4 4 Customer Installed Aftertreatment Wiring Components 18. 2 3 3 C6 6 Factory Installed Wiring and Components 19. 2 3 4 C6 6 Customer Installed Aftertreatment Wiring Components 20. 2 3 5 C7 1 Factory Installed Wiring and Components 21. 2 3 6 C7 1 Customer Installed Aftertreatment Wiring Components 22. 2 4 ENGINE AFTERTREATMENT COMPONENT LAYOUT DIAGRAMS 23. 2 4 1 C4 4 Principle Engine Electronic Components 23. 2 4 2 C6 6 Principle Engine Electronic Components 24. 2 4 3 C7 1 Principle Engine And Aftertreatment 25, 2 4 4 C7 1 CCEM Principle Electronic Components 26. 3 0 CUSTOMER SYSTEM OVERVIEW KEY ELEMENTS 27,3 1 AFTERTREATMENT CONNECTIONS 27. 3 2 CONNECTION POWER AND GROUNDING 27, 3 3 INDICATION STARTING AND STOPPING THE ENGINE 27. 3 4 CONTROLLING THE ENGINE 28,3 5 AFTERTREATMENT OPERATION AND REGENERATION 28. 3 8 OPTIONAL CUSTOMER INSTALLED COMPONENTS 30, 3 9 TYPICAL CUSTOMER INSTALLED COMPONENT DIAGRAM 31.
3 9 1 Example OEM Schematic 31,3 9 2 Example 1 Basic Engine Application 31. 3 9 3 Example 2 Construction Application 31, 3 9 4 Example 3 Industrial Open Power Unit Application 31. 3 9 5 Example 4 Agricultural Application 31,3 9 6 Example 1 Basic Schematic OEM Harness 32. 3 9 7 Example 2 Construction Schematic OEM Harness 33. 3 9 8 Example 3 IOPU Schematic OEM Harness 34, 3 9 9 Example 4 Agricultural Schematic OEM Harness 35. 4 0 POWER AND GROUNDING CONSIDERATIONS 36,4 1 ENGINE BLOCK GROUNDING 36.
4 1 1 Ground stud on Starter Motor 36, 4 1 2 Ground Connection to Tapping on engine Block 36. 4 1 3 CEM Grounding C7 1 38,4 2 VOLTAGE AND CURRENT REQUIREMENTS 39. Draft Release Version 5 0 Publication TPD1726E1 Page 2 of 260. Created on 07 09 2010 09 38, Electrical Electronic A I Guide Tier 4 Interim C4 4 C7 1 Product Range. 4 3 ECM POWER SUPPLY CIRCUIT RESISTANCE 40, 4 3 1 Important Voltage Supply Circuit Considerations 42. 4 3 2 Battery Connection 42,4 3 3 Battery Connection 44.
4 3 4 Correct method of ECM battery connection 45, 4 3 5 Incorrect method of ECM battery connection 45. 4 4 ENGINE ECM POWER SUPPLY CIRCUIT RESISTANCE TEST 46. 4 4 1 Test Procedure 47,4 4 2 Suppression of Voltage Transients 47. 4 5 DIRECT BATTERY CONNECTION REQUIREMENTS 49, 4 6 POWERING THE ENGINE ECM VIA AUXILIARY POWER SUPPLIES 49. 4 7 SENSOR COMMON CONNECTIONS 49,4 7 1 Actuator Driver Return 50. 4 7 2 Analogue Sensor Return 50,4 7 3 Switch Return 50.
4 7 4 Digital Return 51,4 8 MANDATORY FUEL LIFT PUMP INSTALLATION 51. 4 8 1 Fuel Lift Pump Operation 51,4 8 2 Fuel Lift Pump Configuration 51. 4 8 3 Fuel Lift Pump Installation 52,5 0 CONNECTORS AND WIRING HARNESS REQUIREMENTS 54. 5 1 ENGINE ECM J1 CONNECTOR 54,5 1 1 Connector Layout 55. 5 1 2 Tightening the OEM Connector 55,5 1 3 ECM connector Wire Gauge Size 55.
5 1 4 Terminal Retention 56, 5 1 5 Hand Crimping For Prototype machines and Low Volume Production 56. 5 1 6 ECM connector sealing plug installation guidelines 56. 5 1 7 OEM harness Dress Cover With Integrated Strain Relief 56. 5 1 8 Machine Crimping For High Volume Production 57. 5 2 ENGINE TO AFTERTREATMENT CONNECTORS C7 1 ONLY 58. 5 2 1 40 Way CEM Connector Layout C7 1 58, 5 2 2 Engine Harness 31 pin Connector Layout C7 1 59. 5 2 3 Tightening the Connectors 59, 5 2 4 Aftertreatment Connectors Wire Gauge Size 59. 5 2 5 Connector Sealing Plug Installation Guidelines 60. 5 2 6 OEM Harness Retention 60,5 2 7 Harness Routing and Length Restrictions 60. 5 3 DIAGNOSTIC CONNECTOR 61,5 3 1 Diagnostic Connector Layout 61.
5 3 2 Diagnostic Connector Wire Gauge Size 62,5 3 3 Pin Information 62. 5 4 CONNECTOR TERMINAL CONTACTS 63,5 5 HARNESS WIRING STANDARDS 64. 5 4 1 Connectors 64,5 4 2 Harness Bends Near Connectors 64. 5 4 3 Cable routing 65,5 4 5 Electromagnetic Compliance EMC 66. 5 4 6 Insulation Selection and Thermal Protection 66. 6 0 CONNECTING TO ENGINE AFTERTREATMENT 67, 6 1 C4 4 AND C6 6 EMISSION CRITICAL AFTERTREATMENT INSTALLATION 68.
6 1 1 Low Temperature Regeneration System Overview 68. 6 1 2 Low Temperature Regeneration 69,6 1 3 System Connection and Harness Design 70. 6 1 4 Aftertreatment Wiring Schematic 71,6 2 C7 1 EMISSION CRITICAL AFTERTREATMENT 72. 6 2 1 High Temperature Regenerations System Overview 72. 6 2 2 High Temperature ARD Regeneration 73, Draft Release Version 5 0 Publication TPD1726E1 Page 3 of 260. Created on 07 09 2010 09 38, Electrical Electronic A I Guide Tier 4 Interim C4 4 C7 1 Product Range. 6 2 3 C7 1 High Temperature Regeneration System Connection and Harness Design 74. 6 2 4 Aftertreatment Wiring Schematic 78, 6 4 AUXILIARY SENSOR INSTALLATION AND CONNECTION 79.
6 4 1 DPF Soot Sensor 79,6 4 2 Air Inlet Temperature Sensor 83. 6 4 3 DPF Inlet Temperature Sensor 84,6 4 4 DPF Identification Module 86. 6 4 5 ARD Fuel Pump 87,7 0 STARTING AND STOPPING THE ENGINE 92. 7 1 STARTING THE ENGINE 92,7 2 STOPPING THE ENGINE AND PREVENTING RESTART 93. 7 2 1 Ignition Keyswitch 93,7 2 2 Battery Isolation Switches 94.
7 2 3 User Defined Shutdown Switch Remote Shutdown 94. 7 2 4 Intake Air Shutoff Valve 95,7 2 5 Overspeed Verify Switch 96. 7 2 6 Datalink stops 96, 7 2 7 Common problems with the application of stop devices 97. 8 0 MACHINE FAN CONTROL 98,8 1 HYDRAULIC FAN CONTROL 98. 8 1 1 Hydraulic Fan Operation 98,8 1 2 Hydraulic Fan Configuration 98. 8 1 3 Hydraulic Fan Installation 98,8 2 VISCOUS FAN CONTROL 99.
8 2 1 Viscous Fan Operation 99,8 2 2 Viscous Fan Configuration 99. 8 2 3 Viscous Fan Installation 99,9 0 ENGINE SPEED DEMAND 100. 9 1 ANALOGUE SENSOR 101,9 1 1 Analogue Sensor Operation 101. 9 1 2 Analogue Sensor Configuration 101,9 1 3 Analogue Sensor Installation 102. 9 1 4 Evaluating Component Compatibility Testing 102. 9 2 PWM SENSOR COMPATIBILITY 105,9 2 1 PWM Sensor Operation 105.
9 2 2 PWM Sensor Configuration 106,9 2 3 PWM Sensor Installation 106. 9 3 THROTTLE LOCK PTO MODE 107,9 3 1 Throttle Lock Mode Operation 107. 9 3 2 Throttle Lock Mode Configuration 111,9 3 2 Throttle Lock Mode Installation 111. 9 3 3 Throttle Lock Operation Under Engine Load 112. 9 4 MULTI POSITION THROTTLE SWITCH MPTS 113,9 4 1 MPTS Operation 113. 9 4 2 MPTS Configuration 114,9 4 3 MPTS Installation 114.
9 5 TORQUE SPEED CONTROL TSC1 SPEED CONTROL OVER CAN 115. 9 6 ARBITRATION OF SPEED DEMAND 115,9 6 1 Manual Throttle Selection Switch 115. 9 7 ACCELERATION AND DECELERATION RAMP RATES 115, 9 8 THROTTLE BEHAVIOR DURING ENGINE GOVERNOR CHANGES 116. 9 9 1 Throttle Parameter Description 119,9 9 2 Throttle Calibration Function 120. 9 9 3 Idle Validation Switch 124,9 10 DEFINITION OF ENGINE SPEED POINTS 125. 9 10 1 Engine Low Idle 126, Draft Release Version 5 0 Publication TPD1726E1 Page 4 of 260.
Created on 07 09 2010 09 38, Electrical Electronic A I Guide Tier 4 Interim C4 4 C7 1 Product Range. 9 10 2 Engine High Idle 126,9 10 3 Engine Rated Speed 127. 10 0 COLD WEATHER ENGINE OPERATION STARTING AIDS 128. 10 1 CONTROL OF GLOW PLUGS BY THE ENGINE ECM 130,10 1 1 Glow Plug System Operation 130. 10 1 2 Glow Plug System Configuration 132,10 1 3 Glow Plug System Installation 132. 10 2 ETHER COLD START SYSTEMS 134,10 2 1 Ether start Operation 134.
10 2 2 Ether start Configuration 134,10 2 3 Ether start Installation 134. 10 3 REGENERATION AID FOR COLD TEMPERATURE OPERATION 136. 11 0 ENGINE AFTERTREATMENT MONITORING HIGH LEVEL,INDICATORS OPERATOR DISPLAYS 137. 11 1 ENGINE MANAGEMENT SYSTEM STATUS INDICATION 137. 11 1 1 Engine Monitoring System Fault Status Levels 137. 11 1 2 Hardwired Lamp Monitoring System Display 138. 11 1 3 Data Link Driven J1939 Monitoring System Display 138. 11 2 GAUGE DRIVERS 140,11 2 1 Datalink Driven Intelligent Displays 140. 11 2 2 Minimum Functional Specification for J1939 display 140. 11 2 3 Customer Triggered Engine Fault codes 141,11 3 LAMP OUTPUTS 142. 11 3 1 ISO Reference For Aftertreatment Symbols 142. 11 3 2 Indicator lamps Logic 143,11 3 3 Engine Shutdown Lamp 146.
11 3 4 Engine Warning Lamp 146,11 3 5 Wait to Start Lamp 147. 11 3 6 Low Oil Pressure Lamp 147,11 3 7 DPF Lamp 148. 11 3 8 HEST High Exhaust System Temperature Lamp 148. 11 3 9 DPF Regeneration Disable lamp 149,11 4 ACTIVATION OF J1939 INDICATORS 150. 12 0 ENGINE AND AFTERTREATMENT MONITORING SYSTEM 151. 12 1 GENERAL INFORMATION 151,12 1 1 Engine Monitoring Level 151. 12 1 2 Parameter Severity Levels 152,12 1 3 Monitoring System Example 153.
12 2 ENGINE MONITORING PROTECTION 154,12 2 1 Coolant Temperature 154. 12 2 2 Engine Oil Pressure 155,12 2 3 Intake Manifold Temperature 156. 12 2 4 Engine Overspeed 157,12 3 AFTERTREATMENT MONITORING PROTECTION 158. 13 0 MONITORED INPUTS FOR CUSTOMER FITTED SENSORS 159. 13 1 AIR FILTER SERVICE INDICATOR AIR INTAKE RESTRICTION SWITCH 160. 13 1 1 Air Intake Restriction Switch Operation 160. 13 1 2 Air Intake Restriction Switch Configuration 161. 13 1 3 Air Intake Restriction Switch Installation 161. 13 2 COOLANT LEVEL SWITCH 162,13 2 1 Coolant Level Switch Operation 162. 13 2 2 Coolant Level Switch Configuration 162,13 2 3 Coolant Level Switch Installation 163.
13 3 WATER IN FUEL TRAP SWITCH 164,13 3 1 Water In Fuel Trap Switch Operation 164. Draft Release Version 5 0 Publication TPD1726E1 Page 5 of 260. Created on 07 09 2010 09 38, Electrical Electronic A I Guide Tier 4 Interim C4 4 C7 1 Product Range. 13 3 2 Water In Fuel Trap Switch Configuration 164. 13 3 3 Water In Fuel Trap Switch Installation 164,13 4 AUXILIARY TEMPERATURE SENSOR 165. 13 4 1 Auxiliary Temperature Sensor Operation 165, 13 4 2 Auxiliary Temperature Sensor Configuration 165. 13 4 3 Auxiliary temperature Sensor Installation 166. 13 5 AUXILIARY PRESSURE SENSOR 168,13 5 1 Auxiliary Pressure Sensor Operation 168.
13 5 2 Auxiliary Pressure Sensor Configuration 168. 13 5 3 Auxiliary pressure Sensor Installation 169,13 6 OIL LEVEL SWITCH 170. 13 6 1 Oil Level Switch Operation 170,13 6 2 Oil Level Switch Configuration 170. 13 6 3 Oil Level Switch Installation 170,13 7 FUEL FILTER DIFFERENTIAL PRESSURE SWITCH 171. 13 7 1 Fuel Filter Differential Pressure Switch Operation 171. 13 7 2 Fuel Filter Differential Pressure Switch Configuration 172. 13 7 3 Fuel Filter Differential Pressure Switch Installation 172. 14 0 REGENERATION SYSTEM CUSTOMER INTERFACE 174, 14 1 LOW TEMPERATURE REGENERATION SYSTEM OPERATION 174. 14 1 1 Low Temperature Regeneration System Overview 174. 14 2 LOW TEMPERATURE REGENERATION OPERATOR INTERFACE 175. 14 2 1 Low Temp Regeneration Lamp Strategy 175, 14 3 LOW TEMPERATURE REGENERATION SYSTEM OPERATION EXAMPLE 175.
14 4 HIGH TEMPERATURE DPF REGENERATION SYSTEM OPERATION 177. 14 4 1 High Temperature Regeneration System Overview 177. 14 5 HIGH TEMPERATURE REGENERATION SYSTEM CUSTOMER INTERFACE 181. 14 5 1 Lamp Strategy 181,14 5 2 Regeneration Interface Switch 182. 14 5 3 OK To Elevate Idle Input 183, 14 5 4 High Speed Regeneration Enable Input HSR Input 184. 14 5 5 DPF Soot Loading Indicator 185, 14 5 6 Integrated Machine Solutions Over J1939 186. 14 6 TOTAL SYSTEM OPERATION EXAMPLE 187,15 0 ENGINE GOVERNOR 190. 15 1 MIN MAX GOVERNING 190,15 1 1 Operation 190,15 1 2 Configuration 191.
15 1 3 Installation 191,15 2 ALL SPEED 192,15 2 1 Operation 192. 15 2 2 Configuration 194,15 2 3 Installation 194,15 3 AUXILIARY GOVERNOR 194. 15 4 RATING SELECTION VIA SERVICE TOOL 194, 15 5 ENGINE HIGH SPEED GOVERNOR GOVERNOR RUN OUT 195. 15 5 1 Engine High Speed Governor Operation 195, 15 5 2 Engine High Speed Governor Configuration 195. 15 6 MODE SELECTION 195,15 6 1 Operation 195,15 6 2 Configuration 196.
15 6 3 Installation 196, 15 6 4 Rating and Droop changes requested via the J1939 datalink 197. 16 0 TIER 4 INTERIM SERVICE TOOL FEATURES 198,16 1 INTRODUCTION 198. 16 2 SERVICE TOOL FEATURES FOR A C7 1 198, Draft Release Version 5 0 Publication TPD1726E1 Page 6 of 260. Created on 07 09 2010 09 38, Electrical Electronic A I Guide Tier 4 Interim C4 4 C7 1 Product Range. 16 3 SERVICE TOOL FEATURES FOR A C4 4 C6 6 198,17 0 DATALINK SUPPORT 199.
17 1 SAE J1939 199, 17 1 1 Summary of Key J1939 Application Issues 199. 17 1 2 Physical layer 199,17 1 3 Network Layer 200. 17 1 4 Application Layer 200,17 2 CONNECTION AND USE OF THE J1939 CAN BUS 201. 18 0 J1939 SUPPORTED PARAMETERS QUICK REFERENCE 202. 19 0 J1939 PARAMETERS DETAILED DESCRIPTIONS 211,19 1 SENDING MESSAGES TO THE ENGINE ECM 211. Caterpillar C4 4 C6 6 amp C7 1 Tier 4 Interim Series ELECTRICAL amp ELECTRONIC A amp I GUIDE Four amp Six cylinder diesel engines for agricultural industrial construction applications Developed to meet EEC off road mobile machinery Stage IIIB and EPA off road Tier 4 Interim

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