The electronic control system has the following components:
- ECM
- Pressure sensors
- Temperature sensors
- Crankshaft speed/timing sensors
Illustration 2 is a block diagram of the control system on a normally aspirated engine. Illustrations 1 and 3 are block diagrams of the control system on turbocharged engines.
Block diagram for the C1.5 engine
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| Illustration 1 | g03339508 |
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Typical example (1) Air cleaner (2) Air inlet temperature sensor (3) Aftertreatment Regeneration Device (ARD) air pump (4) ARD glow plug relay (5) Diesel Particulate Filter (DPF) differential pressure sensor (6) ARD glow plug (7) ARD combustion chamber temperature sensor (8) Turbocharger (9) ARD combustion chamber (10) Diesel Oxidation Catalyst (DOC) and DPF (11) DOC inlet temperature sensor (12) DPF inlet temperature sensor (13) DPF outlet temperature sensor (14) Boost pressure sensor (15) ARD body (16) ARD injector No.1 (17) ARD injector No.2 (18) Injector leak-off return line (19) Coolant temperature sensor (20) Primary speed sensor (21) Electronic Control Module (ECM) (22) Engine (23) Oil pressure switch (24) Engine glow plug relay (25) Fuel injection pump and fuel control rack (26) Fuel rack actuator (27) Fuel rack position sensor (28) Fuel transfer pump (29) Secondary fuel filter (30) Primary fuel filter (31) In line fuel filter (32) Fuel tank (33) Fuel restrictor | |
Block diagram for the C2.2 engine
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| Illustration 2 | g03339507 |
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Typical example (1) Air cleaner (2) Air inlet temperature sensor (3) Aftertreatment Regeneration Device (ARD) air pump (4) ARD glow plug relay (5) Diesel Particulate Filter (DPF) differential pressure sensor (6) ARD glow plug (7) ARD combustion chamber temperature sensor (8) ARD combustion chamber (9) Diesel Oxidation Catalyst (DOC) and DPF (10) DOC inlet temperature sensor (11) DPF inlet temperature sensor (12) DPF outlet temperature sensor (13) ARD body (14) ARD injector No.1 (15) ARD injector No.2 (16) Injector leak-off return line (17) Coolant temperature sensor (18) Primary speed sensor (19) Electronic Control Module (ECM) (20) Engine (21) Oil pressure switch (22) Engine glow plug relay (23) Fuel injection pump and fuel control rack (24) Fuel rack actuator (25) Fuel rack position sensor (26) Fuel transfer pump (27) Secondary fuel filter (28) Primary fuel filter (29) In line fuel filter (30) Fuel tank (31) Fuel restrictor | |
Block diagram for the C2.2T engine
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| Illustration 3 | g03339510 |
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Typical example (1) Air cleaner (2) Air inlet temperature sensor (3) Aftertreatment Regeneration Device (ARD) air pump (4) ARD glow plug relay (5) Diesel Particulate Filter (DPF) differential pressure sensor (6) ARD glow plug (7) ARD combustion chamber temperature sensor (8) Turbocharger (9) ARD combustion chamber (10) Diesel Oxidation Catalyst (DOC) and DPF (11) DOC inlet temperature sensor (12) DPF inlet temperature sensor (13) DPF outlet temperature sensor (14) Boost pressure sensor (15) ARD body (16) ARD injector No.1 (17) ARD injector No.2 (18) Valve for the NOx Reduction System (NRS) (19) Exhaust gas cooler (NRS) (20) Injector leak-off return line (21) Coolant temperature sensor (22) Primary speed sensor (23) Electronic Control Module (ECM) (24) Engine (25) Oil pressure switch (26) Engine glow plug relay (27) Fuel injection pump and fuel control rack (28) Fuel rack actuator (29) Fuel rack position sensor (30) Fuel transfer pump (31) Secondary fuel filter (32) Primary fuel filter (33) In line fuel filter (34) Fuel tank (35) Fuel restrictor | |
Sensor Locations for the Engine
The illustrations in this section show the typical locations of the sensors for the industrial engine. Specific engines may appear different from the illustration due to differences in applications.
Note: In the following illustrations, some components have been removed in order to improve visibility.
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| Illustration 4 | g03339512 |
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Sensor locations on the left side of the C1.5 engine (1) Coolant temperature sensor (2) Primary speed sensor | |
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| Illustration 5 | g03339513 |
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Close up views of sensor locations on the left side of the C1.5 engine (1) Coolant temperature sensor (2) Primary speed sensor | |
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| Illustration 6 | g03339514 |
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Sensor and component locations on the top and right side of the C1.5 engine (3) DPF differential pressure sensor (4) ARD glow plug (5) ARD glow plug resistor (6) Boost pressure sensor (if equipped) (7) Oil pressure switch (8) Air inlet temperature sensor (9) ARD air pump (10) Secondary speed sensor (11) Fuel injection pump and fuel control rack (12) Fuel rack solenoid and position sensor (13) Electric fuel priming pump | |
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| Illustration 7 | g03339515 |
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Close-up views of sensor and component locations on the top and right side of the C1.5 engine (3) DPF differential pressure sensor (4) ARD glow plug (5) ARD glow plug resistor (6) Boost pressure sensor (if equipped) (7) Oil pressure switch (8) Air inlet temperature sensor (9) ARD air pump (10) Secondary speed sensor (11) Fuel pump and fuel rack (12) Fuel rack solenoid and position sensor (13) Electric fuel lift pump | |
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| Illustration 8 | g03339516 |
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Typical sensor locations on the left side of the C2.2 engines (14) Coolant temperature sensor (15) Primary speed sensor | |
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| Illustration 9 | g03339517 |
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Close-up views of typical sensor locations on the left side of the C2.2 engines (14) Coolant temperature sensor (15) Primary speed sensor | |
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| Illustration 10 | g03339518 |
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Typical sensor locations on the right side and top of the C2.2 engines (16) DPF differential pressure sensor (17) ARD glow plug (18) Boost pressure sensor (if equipped) (19) Oil pressure switch (20) Air inlet temperature sensor (21) ARD air pump (22) Secondary speed sensor (23) Fuel injection pump and fuel control rack (24) Fuel rack solenoid and position sensor (25) Electric fuel priming pump | |
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| Illustration 11 | g03339520 |
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Close-up views of typical sensor locations on the right side and top of the C2.2 engines (16) DPF differential pressure sensor (17) ARD glow plug (18) Boost pressure sensor (if equipped) (19) Oil pressure switch (20) Air inlet temperature sensor (21) ARD air pump (22) Secondary speed sensor (23) Fuel injection pump and fuel control rack (24) Fuel rack solenoid and position sensor (25) Electric fuel priming pump | |
Sensor Locations for the Clean Emissions Module
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| Illustration 12 | g03339521 |
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Sensors and components on a typical Clean Emissions Module (CEM) (1) DPF outlet pressure connection (2) DPF intake pressure connection (3) DOC intake temperature sensor (4) DPF intake temperature sensor (5) DPF outlet temperature sensor | |
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| Illustration 13 | g03322430 |
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Typical example | |
The Electronic Control Module (ECM) (1) functions as a computer for the fuel system.
The electronic system consists of the ECM, the engine sensors, and inputs from the application. The ECM is the computer. The flash file is the software for the computer. The flash file contains the operating maps. The operating maps define the following characteristics of the engine:
- Engine rating
- Torque curves
- High and low idle speed (rpm)
- Emissions
The ECM has an excellent record of reliability. Any problems in the system are most likely to be the connectors and the wiring harness. The ECM should be the last item in troubleshooting the engine.
The programmable software contains all the fuel setting information. The information determines the engine performance.
Flash programming is the method of programming or updating the programmable software. Refer to Troubleshooting, "Flash Programming" for the instructions on the flash programming of the programmable software.
The ECM is sealed and the ECM needs no routine adjustment or maintenance.
The ECM has software that compares the desired engine speed to the actual engine speed. The actual engine speed is determined through the crankshaft speed sensor. If the desired engine speed is greater than the actual engine speed, the ECM will instruct the fuel injection pump to supply more fuel to the fuel injectors in order to increase engine speed.
The programmable software inside the ECM sets certain limits on the amount of fuel that can be provided to the fuel injectors.
The ECM controls the following characteristics:
- Operation of the NOx reduction system (if equipped)
- Regeneration
When the ECM detects an electronic system problem, the ECM generates a diagnostic code. Also, the ECM logs the diagnostic code in order to indicate the time of the problem's occurrence. The ECM also logs the number of occurrences of the problem. Diagnostic codes are provided in order to indicate that the ECM has detected an electrical problem or an electronic problem with the engine control system. In some cases, the engine performance can be affected when the condition that is causing the code exists.
If the operator indicates that a performance problem occurs, the diagnostic code may indicate the cause of the problem. Use a laptop computer to access the diagnostic codes. The problem should then be corrected.
Event Codes are used to indicate that the ECM has detected an abnormal engine operating condition. The ECM will log the occurrence of the event code. This does not indicate an electrical malfunction or an electronic malfunction. If the temperature of the coolant in the engine is higher than the permitted limit, then the ECM will detect the condition. The ECM will then log an event code for the condition.
The engine has two speed sensors installed to measure crankshaft speed.
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| Illustration 14 | g03323793 |
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Typical example | |
The primary speed sensor (1) is located on the left-hand side of the engine towards the bottom of the front housing.
The primary speed sensor generates a signal by detecting the movement of the crankshaft. The signal that is generated by the speed sensor is transmitted to the ECM.
The ECM uses the signal from the speed sensor to determine the engine speed.
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| Illustration 15 | g03323794 |
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Typical example | |
The secondary speed sensor (2) is located on the right-hand side of the engine towards the top of the front housing.
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| Illustration 16 | g03323790 |
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Typical example | |
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| Illustration 17 | g03323797 |
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Typical example | |
The boost pressure sensor is an active sensor.
The boost pressure sensor provides the ECM with a measurement of inlet manifold pressure.
The operating range of the boost pressure sensor is
The engine oil pressure switch provides the ECM with a measurement of engine oil pressure. The ECM can warn the operator of possible conditions that can damage the engine. This includes the detection of an oil filter that is blocked.
The engine oil pressure switch is operated when a pressure of
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| Illustration 18 | g03323798 |
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Typical example | |
The air inlet temperature sensor and the coolant temperature sensor are passive sensors. Each sensor provides a temperature input to the ECM. The ECM controls following operations:
- Fuel delivery
The operating range for the sensors ...
The sensors are also used for engine monitoring.