Service Training

SEBV2588
February 1993

SLIDE/TEXT REFERENCE

3508 EUI SYSTEM COMPONENT DIAGRAM

777C OFF-HIGHWAY TRUCK

J3-18 P3-18 ELECTRONIC ENGINE BLOCK

CONTROL GROUND BOLT
MODULE
(ECM)
MAIN POWER RELAY KEY SWITCH
ELECT UNIT 24 VDC
INJECTORS

15 AMP
J1 BREAKER
BATTERY
P1 AND CHARGING
SYSTEM

ENGINE SPEED / TIMING SENSOR MACHINE

P19 J19 CONNECTOR CAT DATA LINK/SERVICE
COMMUNICATION
TIMING CAL ADAPTER / ECAP
ENGINE COOLANT TEMP SENSOR CONNECTOR SERVICE TOOL
P20 J20 P26 ELEVATED LOW IDLE
ENABLE SWITCH TRANSMISSION

ENGINE OIL PRESSURE SENSOR

P21 J21
THROTTLE BACKUP /
DIAGNOSTIC ENABLE
SWITCH
TURBO COMP. OUTLET PRESSURE SENSOR
P22 J22

TURBO COMP. INLET PRESSURE SENSOR CHECK ENGINE LAMP THROTTLE

ATMOSPHERIC PRESSURE SENSOR
P25 J25 P27 J27
AIR FILTER LAMP
EMS
GROUND LEVEL SHUTDOWN SWITCH
ENGINE OVERSPEED LAMP
OIL PRESSURE LED'S

COOLANT TEMP LED'S

ENGINE OVERSPEED ALARM

ENGINE ON

PART OF TECHNICAL INSTRUCTION MODULE SEGV2588

3500 ELECTRONIC ENGINE CONTROLS

INTRODUCTION
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TABLE OF CONTENTS
INTRODUCTION ...............................................................................................................3
Machine Views...............................................................................................................4
External Engine Views...................................................................................................6

EUI ENGINE COMPONENTS.........................................................................................10

ECM and Personality Module......................................................................................10
Sensors .........................................................................................................................13
Electronic Unit Injector................................................................................................19
EUI and MUI Cylinder Heads .....................................................................................24
Electronic Unit Injector Fuel Flow ..............................................................................23
Two Piece Piston..........................................................................................................25
Lab A - EUI Machine Applications and Engine Component Locations .....................25

MACHINE MOUNTED COMPONENTS........................................................................24

Sensors .........................................................................................................................24
Ground Level Shutdown Switch .................................................................................28
Machine Connector......................................................................................................29

CAB MOUNTED COMPONENTS ..................................................................................30

EMS Panel ...................................................................................................................30
Throttle Position Sensor...............................................................................................32
Service Tool Connector................................................................................................33
Electronic Programmable Transmission Control II ....................................................35
Lab B - Component Location on the Machine (Optional)...........................................35

INCLUDED WITH SLIDE/TEXT REFERENCE

3500 EUI SERVICE TOOL PRESENTATION
Lab C - Tooling Identification .....................................................................................47
Lab D - Engine Component Removal and Installation................................................48

ELECTRONIC CONTROL ANALYZER PROGRAMMER OPERATION

Lab E - System Diagnostics with Training Aid and ECAP .........................................76
Lab F - Engine Diagnostics with ECAP ......................................................................77
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3500 ELECTRONIC ENGINE

CONTROLS
INTRODUCTION

©1993 Caterpillar Inc.

Introduce Course INTRODUCTION

3500 Electronic Engine
Controls This module discusses the 3500 Electronic Engine Controls. The module
covers Electronic Unit Injector (EUI) machine applications, EUI engine
component locations and component functions. Also covered are the
characteristics of the EUI, tooling requirements, the Electronic Control
Analyzer Programmer (ECAP) and the Service Program Module (SPM)
system operation.

The 777C is shown in the slides because it is a current application of the

3500 EUI engine.

The presentations are followed by lab exercises that take place in the
classroom and in the shop on an engine or machine.
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Objective 1 Machine Views

Slides 2 and 3
This slide shows the 777C Off-highway Truck which features the 3508
EUI engine. The 777C Off-highway Truck was introduced in 1992.
Name all current 3500
EUI machine
applications with their
appropriate engines
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793B Off-highway Truck Shown here is the 793B (240 ton) Off-highway Truck parked by the
769C Truck.

The 793B is powered by a 3516 EUI engine. This engine is equipped

with two pairs of series turbochargers and is rated at 1535kW (2057 HP).

This is a summary of 3500 EUI engines in Off-highway Trucks:

777C 3508
785B 3512
789B 3516
793B 3516
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Engine front view External Engine Views

Objectives 2, 3 and 4 The engine block is the same as the mechanical unit injection (MUI)
engine. The primary differences are in the attached components.
Slides 4 - 31

The obvious external difference is the Electronic Control Module

Locate all EUI (ECM) (arrow) which is visible on the left side of the slide.
components on the
engine and machine

Electronic Control
Module (arrow)
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Engine left side View Starting on the left side of the slide notice:
1. Temperature Sensor
2. Wiring Harness The temperature sensor (1) on the thermostat housing.
3. Speed/Timing Sensor
The wiring harness (2) leading to the Deutsch Electrical Connectors
and the injectors.

The Speed/Timing Sensor (3) located on the rear housing.

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Engine Right Side View Starting on the right side of the slide is the wiring harness leading to the
Deutsch electrical connectors on the cylinder heads. The Deutsch
Wiring harness
connectors conduct current to the electronic unit injectors through internal
wiring in the cylinder heads.
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Engine rear view Starting on the left side of the slide are:

1. Rear Housing The rear housing (1) that contains the Speed/Timing sensor.
2. Turbo Outlet
Pressure Sensor The Turbo Outlet (boost) Pressure Sensor (2).
3. Oil Pressure Sensor
The Oil Pressure Sensor (3).
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EUI ENGINE COMPONENTS

ECM and Personality Module

The ECM is mounted in the same position as the hydraulic governor

which was used in earlier applications. A 70 pin connector is located on
the side of the ECM. The 2 pin Deutsch DT connector hanging below
the ECM is used when calibrating the Speed/Timing Sensor. The
warranty is voided if the ECM is opened for any reason other than to
access the personality module.

Explain the function of The ECM is the computer which controls the engine. It sends signals to
the ECM the injectors to regulate the fuel supply to control speed and power. The
ECM contains a personality module.
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The Personality Module is installed below the access panel in the ECM.
The Personality Module contains all the instructions for the ECM such as:
Explain the function of
performance maps, fuel ratio, torque settings, low and high idle, and other
the ECM and
Personality Module settings that are specific to a particular rating of an engine. Production
ECMs will have locking wire sealing the access panel.

When removing or installing the personality module, the power must be

disconnected. After the personality module installation, power must be
supplied to the ECM for at least 30 seconds. This time interval allows the
information to be copied from the personality module to the ECM.

If the wrong personality module is installed in the ECM, an interlock

message will be displayed. This interlock prevents the engine from
starting until the correct personality module is installed.
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10

ECM disassembled for This view of the ECM disassembled shows the position of the Personality
clarity Module. The ECM is a sealed unit and should not be disassembled during
normal maintenance or repair. If the ECM malfunctions, the unit must be
returned for exchange.
Identify the Personality
Module
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11

Sensors
Explain the function of
the Coolant
The Coolant Temperature Sensor (arrow) is mounted on the thermostat
Temperature Sensor
(arrow) housing. The sensor measures the engine temperature from
-40˚C to +121˚C (-40°F to +248°F) and allows the ECM to monitor
engine temperature for cold mode operation.

NOTE: Two basic types of sensors are installed in this system: Analog
and Digital. All temperature and pressure sensors are analog sensors.
Speed/Timing and Throttle Position sensors are digital.
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12

The Speed/Timing Sensor (arrow) is mounted on the left side of the rear
Explain the function of housing. This sensor measures engine speed and timing using a timing
the Speed/Timing
wheel. The Speed/Timing Sensor is also used to identify No. 1 Top Dead
Sensor (arrow)
Center (TDC) during start-up and to detect reverse rotation.
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13

The Speed/Timing Sensor Timing Wheel is shown with the rear

Explain the function of camshaft cover removed. The wheel has a drilled hole which is used for
the Speed/Timing
timing purposes. The hole is positioned over the camshaft dowel.
Sensor Timing Wheel
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14

The Timing Gear is shown with the rear camshaft cover and timing
Explain the function of wheel removed. The Timing Gear is installed on the camshaft taper on
the camshaft dowel and
the end of the camshaft. The locating dowel is used for correct timing
timing gear
wheel alignment with the camshaft.
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15

The Speed/Timing Sensor and Timing Wheel are shown removed from
Explain the function of the engine.
the Speed/Timing
Sensor and Timing
Wheel The Speed/Timing Sensor is self adjusting after the slip-head is extended
prior to installation. The slip-head should be positioned between the
slots, but not in the wide slot. If the sensor is positioned in the wide
slot, it will be destroyed during start-up.

NOTE: The dowel hole is used to align the timing wheel in the correct
timing position on the camshaft. The wide and narrow slots on the timing
wheel are used to determine No. 1 TDC and the correct engine rotation.
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16

The Turbo Outlet Pressure Sensor (1) is mounted in the vee of the
Explain the function of engine. This sensor is used in conjunction with the atmospheric pressure
the sensors
sensor to calculate boost (gauge) pressure. Both sensors measure
1. Turbo Outlet absolute pressure which is checked using the ECAP.
Pressure Sensor
Calibrating the turbo outlet, turbo inlet, and oil pressure sensors takes
2. Oil Pressure Sensor approximately five seconds. To calibrate the sensors, supply power to
the ECM for five seconds without starting the engine. Each sensor
output is set to equal the atmospheric pressure sensor output.

The ECM verifies calibration of the output turbo outlet, turbo inlet, and
oil pressure sensors with the atmospheric pressure sensor reading.

If the engine is started before the five second calibration period, the
calibration is aborted. After replacing the pressure sensors, it is important
to calibrate them.

The Oil Pressure Sensor (2) is mounted on the right side of the engine
block next to the cylinder head. It is used with the Atmospheric Pressure
Sensor to calculate oil (gauge) pressure.
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17

Electronic Unit Injector

This view shows the Electronic Unit Injector with the rocker arm in place.

This EUI injector is mounted the opposite way from the original MUI
injector in order to accommodate the solenoid. The bolt and the clamp
are now mounted toward the outside of the engine (shown in the next
slide).
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18

This view shows the Electronic Unit Injector with the rocker arm
removed.

Injector mounting The clamp holding down the injector can be seen.

The wiring routing enters from the Deutsch connector in the left side of
Cable routing the valve cover base and is routed behind the push rods through a track in
the right side of the base (shown in the picture) to the injector.
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19

1. Solenoid The Electronic Unit Injector is removed from the engine.

2. Injector body
The solenoid, injector body and the nozzle are seen in this view.
3. Nozzle
NOTE: This unit injector has the same bore dimensions as the
Mechanical Unit Injector (MUI). This means that the EUI injector can be
retrofitted to MUI engines which have EUI/MUI heads, which were
introduced in 1992.
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MUI & EUI CYLINDER HEADS

MUI EUI

20

EUI and MUI Cylinder Heads

This slide shows the cylinder head containing the Electronic Unit Injector
next to the cylinder head with the Mechanical Unit Injector. Notice the
EUI injector clamp is on the opposite side from the MUI injector.

All MUI and EUI engines currently in production use the common
EUI/MUI cylinder head.
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ELECTRONIC UNIT INJECTOR

SECONDARY FILTER

ECM

TRANSFER PUMP

FUEL TANK
PRIMARY FILTER

FUEL TANK

21

Electronic Unit Injector Fuel Flow

Explain the function of This slide shows the fuel flow from the tank, through the EUI, and back to
the Electronic Unit the tank. Notice the sequence:
Injector

Fuel is routed through the ECM for cooling purposes. The fuel cools the
ECM by removing heat generated by the circuits and radiated within the
engine compartment. The fuel flow in the EUI engine is the same as the
MUI engine with the exception that the EUI flow is routed through the
ECM.

The Electronic Unit Injector (EUI) is similar to the Mechanical Unit

Injector (MUI). The plungers and barrels have the same dimensions and
the nozzles are similar. The rack and scroll are eliminated from the EUI
system. EUI is controlled by the electronic governor from the wiring
harness. Timing and fuel rate variations are accomplished by varying the
start and duration of the signal to the solenoid.
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The solenoid opens a spill valve which allows fuel to return to the tank, or
closes to allow a pressure increase to inject fuel into the cylinder.

NOTE: Injector parts are not interchangeable and are assembled at the
factory as matched parts. Do not interchange injector parts because the
injector will be out of calibration, causing an overfueling or underfueling
condition in that cylinder.
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22

Two Piece Piston

Explain the function of A two piece piston is used in the EUI engine. Although this design is not
the Two Piece Piston exclusive to the EUI engine, this slide will permit a review of the
construction. The two piece piston has a steel crown and aluminum skirt.
The two parts are joined by the piston pin.

The two piece piston combines the strength of a steel crown to avoid
erosion and the light weight of an aluminum alloy skirt. The steel crown
and pin assembly absorbs combustion loads. The aluminum skirt only
absorbs side loads and friction with the liner.

Introduce and perform Lab A - EUI Machine Applications and Engine Component Locations
Lab A
This classroom and shop lab exercise will reinforce the material covered
Summarize lab by in the previous slide presentation.
reviewing component
locations
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23

MACHINE MOUNTED COMPONENTS

Explain the function of Sensors
the Atmospheric
Pressure Sensor The Atmospheric Pressure Sensor is mounted behind the cab on
Off-highway Trucks. This sensor is used for Automatic Altitude
Compensation, Automatic Filter Compensation, and boost pressure
calculation.

As mentioned earlier, the Atmospheric Pressure Sensor is used in

combination with other sensors.
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24

The Turbo Inlet Pressure Sensor is mounted in the tube between the air
filter and turbocharger. This sensor (arrow) is used with the atmospheric
Explain the function of
pressure sensor for filter differential pressure measurement.
the Turbo Inlet Pressure
Sensor (arrow)
NOTE: The 785B and 793B Trucks have two inlet pressure sensors
because of ducting design.
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25

Ground Level Shutdown Switch

Explain the function of The Ground Level Shutdown switch is used on Off-highway Trucks to
the Ground Level stop the engine in an emergency. The switch can also be used to crank the
Shutdown Switch
engine without fuel for maintenance purposes. Operating the switch to
cause an engine shutdown generates an event on the ECAP.
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26

Machine Connector
Explain the function of The 40 pin Machine Connector (arrow) is mounted on the side of the cab
Machine Connector and is used to connect the engine wiring harness to the machine harness.
(arrow)

NOTE: The engine is delivered with a wiring harness which is long

enough to reach the cab.
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27

CAB MOUNTED COMPONENTS

Explain the EUI EMS Panel
functions of the EMS
Panel
This slide shows the EMS panel which is connected to the EUI system.
The ECM provides an engine running signal to the EMS that was
previously provided by a separate fuel pressure switch. Also, a high
coolant temperature indication signal is supplied by the ECM.
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28

This panel is mounted above the windshield and contains two switches.
Explain the function of
The left switch in the upper position is for the throttle back-up. This
Upper Switch Panel
switch operates the engine in the “limp home mode.” In the lower
position, the switch operates the check engine lamp in the flashing
diagnostic mode.

The right switch enables and disables the cool engine elevated low idle.
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29

Throttle Position Sensor

Explain the function of The Throttle Position Sensor sends a signal to the ECM specifying the
the Throttle Position desired engine speed. The ECM then sends current to the injector
Sensor
solenoids to increase speed until the desired speed is reached.

The Throttle Position Sensor is a integral part of the throttle pedal and
requires no adjustment or maintenance. The sensor output is a digital
Pulse Width Modulated signal (PWM).
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30

Service Tool Connector

Explain the function of The Service Tool Connector is mounted behind the operator’s seat and is
the Service Tool used to connect the ECAP service tool to the machine Data Link.
Connector

The data link enables the ECM, ECAP, EPTC II transmission control and
other components (such as VIMS) to share data on a common system.
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31

ECAP and Service Tool Connector

Explain how the ECAP The ECAP service tool is connected to the Communications Adapter. The
and Service Tool Communications Adapter is connected to the Service Tool Connector
Connector work
behind the operator’s seat on the truck. The ECAP is similar to a laptop
together
computer and is a multi-function tool replacing many existing tools. The
ECAP is used to perform diagnostic tasks and show the status of the
engine and transmission electronics.
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32

Electronic Programmable Transmission Control II

The Electronic Programmable Transmission Control is located behind the

Explain the function of operator’s seat to the left of the service connector. The control is
the EPTC II
connected to the ECM by the CAT Data Link.

The EPTC II control differs from the previous transmission control in that
it signals the ECM to reduce engine speed during upshifts and to increase
engine speed during downshifts. This feature reduces driveline and
operator stress. This function is called "Controlled Throttle Shift."

Another feature of the system is "Directional Shift Management" which

lowers engine rpm to low idle when a shift is made from idle to first or
reverse. This feature reduces wear caused by operator abuse.

A third feature is "Neutral Coast Inhibit" which is designed to prevent

high speed coasting.

INSTRUCTOR NOTE: For additional information on the EPTC II,

Introduce and perform
refer to the Technical Instruction Module "Electronic Programmable
Lab B
Transmission Control II" (Form SEGV2584).
Summarize lab by
reviewing component Lab B - Component Location on the Machine (Optional)
locations
This shop lab exercise will reinforce the material covered in the previous
slide presentation.
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TOOLING PRESENTATION

INSTRUCTOR NOTE In the Preparation Checklist and in this presentation is a list of tools that
are used on the 3500 EUI engines. The list, with a few exceptions,
includes only those tools that are used on the 3500 EUI system.

The purpose of this tooling presentation is to introduce EUI tooling to the

students. It is not an in depth study, but it does teach the student to
recognize the tooling and explain the purpose of each tool used in the
module.

A copy of the Service literature appropriate for each tool should be on

hand and can be given to the students as handouts if desired.

It should be noted that no slides are provided for the tooling

presentation. The actual tools should be used and shown to the class.

The following list summarizes the recommended tools for this

presentation:

ECAP
Communication Adapter
Caterpillar Multimeter
Timing and Fuel Setting Tool Group
Deutsch Connector Kit
Cable Probes and Breakout Harnesses

A detailed list of tools for 3500 EUI engines follows on the next page.
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3500 EUI SERVICE TOOL LIST

1. ELECTRICAL / ELECTRONIC TOOLS

PART NO. DESCRIPTION

8T8697 ECAP
7X1180 ECAP Internal Expansion Board
(necessary if all slots are full)
7X1700 Communication Adapter
7X1703 ECAP Mounting for Communication Adapter
7X1570 Communication Adapter Cable
7X1420 Communication Adapter Cable
7X1695 Timing Probe Cable
6V2197 Timing Probe Magnetic Pickup
6V3093 Timing Probe Adapter Sleeve
8C9801 PWM Signal Adapter Group
7X1710 Signal Reading Probe Group
(can replace Breakout Cables)
4C3406 Deutsch Connector Repair Kit
(does not include DT Connectors)
6V7070 Caterpillar Digital Multimeter

NEXG4521 3500 EUI Engine Service Program Module

(media subscription only)
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2. MECHANICAL TOOLS

PART NO. DESCRIPTION

9U5132 Timing and Fuel Setting Tool Group (EUI/MUI

Pump Height Adjustment Tool Group -
Replaces 6V7880)

NOTE: Order the following parts to update the existing 6V7880 Tool Kit
for EUI/MUI engines.

9U5233 Magnetic Fixture Group

(replaces 9U5137)
9U5138 Gauge Block
9U6044 Solenoid Driver (Injector terminal nut spinner)
6V3072 Plastic Case
9U5136 Foam Insert
NEEG2515 Decal Label

1U6661 Unit Injector Tester

1U6665 Power Supply
9U6143 Upgrade Adapter for IU6665

NOTE: The above three part numbers are necessary to test the 3500 EUI
unit injectors. This equipment may be also used to test 3176 and 3406
unit injectors.

Injector Holding Block (not announced yet)

3. OPTIONAL ELECTRICAL AND DIAGNOSTIC TOOLS

PART NO. DESCRIPTION

8T8726 3 Pin Breakout Cable for Deutsch HD10

Connectors (round type)
9X1160 40 Pin Breakout Cable
4C6090 Multichannel Temperature Selector Group
(Pyrometer)
8C9700 Printer Group for the ECAP (available 4/93)
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SHOW
THE ECAP

Objective 5 Electronic Control Analyzer Programmer (ECAP)

Explain the use of the The ECAP is a multipurpose tool that does the work of about a dozen
ECAP
previously used tools. This is possible because the EUI electronic control
system contains sensors and determines other parameters such as fuel
position and timing. (An ECAP demonstration and explanation is given
in the next section of this presentation.)

The ECAP functions similarly to a normal Personal Computer (PC). The

ECAP provides a series of menus to guide you through the various ECAP
tasks.

The ECAP is self contained in its own case. Some ECAP features
include:

• An eight line by 80 column screen that displays information and

messages.
• An 84 key keyboard in standard typewriter layout.
• A port for communication with electronic controls or computers.
• A port for communication with modems, printers, computers, or
controls.
• A port for temporary addition of application programs.
• A service program used to service a variety of electronic controls.
• Additional service programs can be permanently installed.
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SHOW THE
COMMUNICATION
ADAPTER

Communication Adapter
Explain the use of the On the 3500 EUI engine, the ECAP is used with the communication
Communication
adapter.
Adapter

The Communication Adapter provides a common link between the ECAP

and the Electronic Control Module (ECM).

The Communication Adapter is necessary because the ECAP does not

share the same communication link used on Cat equipment. The two
links are: Cat Data Link, and a standard link set up by the Society of
Automotive Engineers (SAE) and the American Trucking Association
(ATA) called the "SAE J1587 Data Link."
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SHOW
THE CATERPILLAR
MULTIMETER

Caterpillar Multimeter
Explain the use of the
Caterpillar Multimeter The Caterpillar Multimeter is an essential part of the tooling for this
engine. After the ECAP, it is the most used part of the tooling.

Although the EUI system is electronic, the electronic parts do not need
routine maintenance. Therefore, only the electrical work remains, which
is performed with the Multimeter.
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SHOW
THE TIMING AND
FUEL SETTING
TOOL GROUP

Timing and Fuel Setting Tool Group

Explain the use of the
Timing and Fuel Setting The 9U5132 tool group is only used to set injector height on the 3500 EUI
Tool Group engine and is similar to the previous Timing and Fuel Setting Group for
the 3500 MUI engine. It also services the MUI engine.

The tool group is no longer required to perform the fuel setting or injector
timing on the EUI engine because this function is now performed by the
ECAP.

The box has a space reserved for the digital dial indicator which is an
option with the group.

If necessary, the existing 3500 Timing and Fuel Setting Tool Group
6V7880 can be updated to the new standard using the list provided in the
Student Material. This change enables the tool group to be used on both
EUI and MUI engines.
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SHOW
THE DEUTSCH
CONNECTOR KIT

Deutsch Connector Kit

Explain the use of the Two types of connectors are used on the EUI engine: the DT (square,
Deutsch Connector Kit rectangular or triangular) connector and the HD10 (round). The HD10 is
the standard connector on the 3500 EUI with the exception of the unit
injection and timing calibration connectors.

The Deutsch Connector has been designed to give reliable service in a

harsh environment. It was originally selected by Caterpillar for use on
PEEC and the 3176 engines after extensive testing. Tests conducted
include the following:

1. Maintenance, aging
2. Durability
3. Contact retention
4. Vibration
5. Insulation resistance
6. Contact resistance
7. Thermal shock
8. Temperature life
9. Fluid resistance
10. Water immersion
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SHOW
THE CABLE PROBES
AND BREAKOUT
HARNESSES

Cable Probes and Breakout Harnesses

Explain the use of the It is recommended that the cable probes are used with the tool kit for this
Cable Probes and engine. Also useful, but not completely necessary, are the breakout
Breakout harness
harnesses. These tools are helpful, for instance, when checking out the
power supply to a sensor and checking the output simultaneously.

One drawback is possible with the breakout harness. If the fault is in the
plug or socket, the act of disconnection may either solve the problem or
the problem may not be found. With the cable probe, the pins and sockets
are not disturbed.

The connection should be inspected. Perform a "tug test" and check that
the connector is securely latched, snapped and checked for damage.
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SHOW THE TIMING

CALIBRATION PROBE
AND CABLE

Timing Calibration Probe and Cable

Explain the use of the
Timing Calibration This tool is used to calibrate the speed/timing sensor circuit. The cable is
Probe and Cable connected to the DT connector below the ECM. The other end of the
cable is connected to the probe which is installed in the flywheel housing
at the same location used to perform static pin timing.

Calibration is performed automatically using the ECAP.

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SHOW
THE MULTICHANNEL
TEMPERATURE
SELECTOR GROUP

Multichannel Temperature Selector Group

Explain the use of the This tool, although not an essential part of the tooling, provides an
Multichannel excellent means of troubleshooting a mechanical cylinder problem on
Temperature Selector
MUI and EUI engines.
Group

The tool enables the technician to measure all cylinder temperatures

simultaneously. This helps identify a cylinder which is not firing due to a
mechanical problem.

The tool is useful to determine the magnitude that a cylinder is low on

power in an EUI engine. The EUI electronic control system contains
diagnostic tests to identify cylinders which are low on power or dead and
whether a problem is mechanical or electrical. This procedure is more
crucial when troubleshooting MUI cylinder problems.

NOTE: Most 3500 engines have exhaust pyrometers installed at the

factory.
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TOOLING
IDENTIFICATION LAB

Introduce and perform Lab C - Tooling Identification

Lab C
This classroom exercise will reinforce the material covered in the
Summarize lab by
reviewing Tooling preceding presentation.
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ENGINE COMPONENT
REMOVAL AND
IDENTIFICATION LAB

Introduce and perform Lab D - Engine Component Removal and Installation

Lab D
This classroom exercise will also reinforce the material covered in the
Summarize lab by
reviewing component preceding presentation.
locations
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ECAP OPERATION PRESENTATION

INSTRUCTOR NOTE The purpose of this presentation is to introduce the Electronic Control
Analyzer Programmer (ECAP) to the students.

A copy of the Service literature appropriate for the ECAP and Service
Program Modules (SPM) should be on hand and can be given to the
students as handouts if desired.

It should be noted that no slides are provided for the ECAP

presentation. The actual ECAP screens should be projected for the
class. This means that if the SPM is updated, the latest screen can still be
shown.

The following list summarizes the recommended tools and equipment for
this presentation:

ECAP
Communication Adapter
Set of cables
Timing sensor calibration probe and cables
Cable Probes and Breakout Harnesses
Laptop computer
Monitor (for labs)
Overhead projector
LCD projector (for projecting ECAP screens)
3500 EUI Training Aid

The presentation should include references to the following Special

Instructions:

Using the 8T8697 ECAP SEHS8742

Using the Machine Functions Service
Program Module SEHS9343

At this point, a good idea is to copy the screen map pages into one large
page format for ease of learning thus permitting the whole picture to be
seen at one time.

The overhead projector should be set up with the Training Aid, ECAP,
and laptop to project the screens for the presentation.
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REMOVE AND
INSTALL ECAP PANEL

Objectives 6 & 7 ECAP OPERATION

ECAP Panel Removal and Installation

Demonstrate and The information supplied in this chapter is not intended to replace the
explain ECAP panel Special Instructions and Service Manuals, but should be used in
removal and Installation conjunction with the relevant service literature, which is the final
authority for service information.

The standard ECAP is equipped with four sockets which hold the
Executive and Service Program Modules (SPM). The ECAP can have up
to eight sockets by installing an extension board. For more than four
SPM's, install the 7X1180 Internal Expansion Board.

The Executive Program is similar to the operating system of a PC. For

the ECAP to function, it must contain the Executive Program. The
Service Program Modules contain information that is specific to an
application.

The ECAP panel and keyboard are secured to the case by eight screws.
To access the Service Program Modules, remove the eight screws and turn
the ECAP panel and Keyboard over.
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REMOVE AND
INSTALL PROGRAM
MODULES

Executive and Service Program Module Removal and Installation

Demonstrate and The ECAP contains an Executive Program Module and a Vehicle Slave
explain removal SPM. These SPM's must be installed in specific slots in the ECAP. The
and installation of
Executive Program Module can only be installed in the "U48" slot. The
program modules
machine slave SPM can only be installed in the "U45" slot.

To remove the SPM, first remove the ECAP panel and pull out the chips
for the SPMs and executive modules. The Special Instruction for the
SPM explains this procedure in detail.

The version number of the SPM is checked using the procedure "SPM
Version Number" in the Special Instruction. Further discussion on finding
the version number is included in the “ECAP Utility Functions.”
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DEMONSTRATE
ECAP AND
COMMUNICATION
ADAPTER
CONNECTIONS

ECAP and Communication Adapter Connections

Demonstrate ECAP and The ECAP and ECM are able to communicate with each other through the
Communication Communication Adapter. The Communication Adapter must be
Adapter connections
connected in series with the Machine Service Connector and the ECAP.

The Engine Service Connector supplies power to the ECAP. A self test is
performed each time that the ECAP is powered up. During this test, the
serial number of the ECAP and the version number of the software
(Executive Program) are displayed. A more detailed self test is performed
by pressing any key during power up.
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DEMONSTRATE
ECAP KEYS

ECAP Keys

Explain the use of the The ECAP functions similarly to other computers and has special keys
ECAP special keys. that are predefined for use.

Note the following key functions:

• LCD viewing angle

• LCD back lighting

INSTRUCTOR NOTE: For an optional Student handout on the special

keys, refer to the Special Instruction "Using the 8T8697 ECAP"
(Form SEHS8742).
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DEMONSTRATE
ECAP LEARN
FUNCTION

ECAP Learn Function

Use the laptop The Special Instruction lists several keys which have special functions to
computer to reproduce make the ECAP easier to use.
ECAP screens
One function not covered in the Special Instruction is the "Learn
Function." The Learn Function is used to return to a specific screen after
power has been removed from the ECAP. The ECAP learns a specific
sequence of key strokes that can be played back at any time by pressing
"F5." After a sequence is loaded, it remains in the memory even when the
ECAP is powered down. A small internal lithium battery powers the
memory when the ECAP is not in use.

A new sequence can be stored any time by repeating the following three
steps. Only one sequence can be stored in the ECAP at a time.

1. Press "SHIFT-F5" keys. The ECAP displays “Learn Mode = ON” on

bottom line of the display screen.

2. Type the desired key sequence.

3. Press " SHIFT-F5" keys. The ECAP displays “Learn Mode = OFF”
on bottom line of the display screen. The sequence is now stored.

NOTE: It is a good idea to select the Main Menu as the first key of a
sequence so the ECAP will start the sequence from the Main Menu
regardless of the current screen when the “F5” key is pressed.
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DEMONSTRATE
ECAP
UTILITY FUNCTIONS
SCREENS

ECAP SCREENS
Demonstrate and ECAP Utility Functions
explain the utility
functions The “Utility Functions” option is the first option displayed on the ECAP
main menu. The Utility Functions are used to change specific ECAP
settings. This presentation provides only a basic discussion of the Utility
Functions. For or a detailed explanation, see the Special Instruction for
using the ECAP.

Utility functions are accessed from the main menu by selecting the
number that corresponds with the Utility Functions option.

Menu items 1, 3 and 4 are used in this course and are explained in the
Special Instruction. The utility functions used in this course are:

1. Communications options - used for communicating with other

computer equipment.
2. SPM Version Numbers - used to display the version numbers of the
SPM's installed in the ECAP.
3. Metric to English - used to select between metric and English display
units.

NOTE: Option 2 is not used on 3500 EUI systems. Option 1

Communication is only used in this course for projecting the ECAP
screens onto a monitor or an overhead projector.
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DEMONSTRATE
3500 EUI SCREEN
MAP

3500 EUI Screen Map

Show the Screen Map Using the 3500 EUI Screen Map in the Tool Operating Manual "Using the
ECAP," a picture of all the screens can be seen.

The screen map and actual ECAP screens displayed on line should be
used for the remainder of the presentation.
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DEMONSTRATE
3500 EUI FUNCTIONS
SCREEN

3500 EUI Functions Screen

Demonstrate the Once “Vehicle Functions” is selected, the following information is
Vehicle Functions displayed on the 3500 EUI Functions screen. The following options are
screen
discussed in the succeeding sections.

Option 1: Read/Change Parameters

Used to view, change, and print parameters stored in the ECM
and view parameter change history. The Vehicle ID and
Engine Serial Number parameters are unprotected and can be
changed without a password. The following parameters are
protected by passwords and can only be viewed without the
passwords: Fuel Ratio Control Offset, Electronic Control
Module Serial Number, Personality Module P/N, Personality
Module Release Date, Full Load Setting, and Full Torque
Setting.

Option 2: Display Status

Displays live values for rpm, pressures, temperatures, etc.

Option 3: Display Diagnostics

Shows Active and Logged (intermittent) Diagnostic and Event
codes. Allows diagnostic codes to be cleared.
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Option 4: Calibrate/Monitor Sensors

Timing sensor calibration

Option 5: Diagnostic Tests

Cylinder Cutout function, Injector solenoid test, Override
Parameters
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DEMONSTRATE
READ/CHANGE
PARAMETERS
SCREEN

Read/Change Parameters
Demonstrate the When "Read/Change Parameters" is selected, the Read/Change
Read/Change Parameters screen is displayed. This screen displays the parameters
Parameters screen
stored in the ECM.

To the right of the parameter value is a tattletale that identifies the number
of times a that parameter has been changed. The total tattletale displayed
at the bottom of the screen identifies the number of times the ECM has
been changed.

When an attempt is made to change a protected parameter, the "Parameter

Change History" screen is displayed.

NOTE: "Protected parameter" means that any changes are logged to

deter unauthorized tampering and provide an audit trail.
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SHOW
PROTECTED
PARAMETERS

Protected Parameters
Demonstrate changing The Full Load Setting/Full Torque Setting, Personality Code, FRC mode
a protected parameter and FRC manual value can be changed. The last ten changes will be
documented in a history log.

NOTE: “Protected” means that changes are logged (see "Parameter

Change History" later in this presentation).

If an ECM must be replaced, all of the programmable parameters must be

recorded (either written down or printed). The Student Materials contain
a worksheet that can be copied and used to record the parameters.

Protected Parameters Caution Screen

This screen will appear when changing protected system parameters.

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DEMONSTRATE
PRINTING
PARAMETERS

Printing Parameters and Screens

When "Print All Parameters" is selected, the ECAP will print the
parameters to a printer connected to ECAP port No. 2.

To print the parameters, select the "Read/Change" menu screen, then

select "Print All Parameters."

To print a particular screen being viewed, press "F6."

NOTE: Refer to the ECAP Special Instruction for RS232 connector pin
definitions.
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SHOW
PARAMETER CHANGE
HISTORY SCREEN

Parameter Change History

Demonstrate the Protected parameters mean that any changes are logged to prevent
Parameter Change tampering. When changes are made, an audit trail is recorded with
History Screen
information about the change. The parameter change history provides a
record of all parameter changes as follows:

• ECM recorded engine hours

• ECAP serial number
• Parameter description
• New Parameter values entered
SEBV2588 - 63 -
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SHOW
DISPLAY STATUS
SCREEN

Display Status Screens

Demonstrate the The "Display Status" screen shows the current operating conditions
Display Status Screen pertaining to the engine at any moment in time. Five standard display
status screens are available.
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DEMONSTRATE
CUSTOMIZING
STATUS SCREENS

Customizing Status Screens

Demonstrate Screens 1 through 5 must be read as as they appear. Screens 6 through 9
Customizing a Display may be customized for convenience, showing all those items of
Status screen.
information which may need to seen simultaneously. These screens, once
configured, may be saved for future use even though the power is
removed from the ECAP. A small battery power supply is incorporated in
the ECAP for this purpose.

NOTE: Screens 1 through 5 are fixed. Screens 6 through 9 may be

customized.

The summary on the following page shows how a sample screen may be
customized with one parameter. Additional parameters may be added
later.

Special Keys To Customize Screens

C (change) = Access the change layout function (in display status)

S (screen) = Screen number selection (i.e. "S6")
P (parameter) = Parameter location area
L (list) = List of available parameters
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Shown below is sample key stroke sequence. Press the keys listed under
ACTION to obtain the listed result.

ACTION RESULT
________________________________________________
1. DISPLAY STATUS from main menu
2. C access to change screen layout function
3. S 6 select Screen 6
4. L select parameter list
5. DOWN ARROW identify battery voltage and parameter no.
6. P parameter location function
7. ARROW to position parameter
8. 30 select battery voltage
9. RETURN to confirm selection
10. PREVIOUS SCREEN to exit function
11. 6 return to Screen 6

Other parameters may be added if desired. The screen is now ready for
use.

After the power is removed from the ECAP, the internal memory will
enable the user to access the re-configured screen No. 6 at a later time.
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SHOW
DIAGNOSTIC
SCREENS

Diagnostic Screens
Demonstrate using the Two categories of diagnostic screens are available:
Diagnostic screens
• Logged/active diagnostic messages
• Logged Events

Logged diagnostic messages provide information on active and logged

failures which are detected by the ECM. The ECM prints the following
information on the screen:

• Fault code CID and FMI (Component ID and Failure mode ID)
• Fault description
• Number of occurrences
• ECM hour of first and last occurrences
• Fault status
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DEMONSTRATE
CLEARING LOGGED
DIAGNOSTICS

Clearing Logged Diagnostic Messages

Demonstrate Clearing Logged diagnostic messages are cleared as follows:
Logged Diagnostics
1. Use the cursor to highlight the message.
2. Press the return key.
3. Press “Y” (yes) to confirm the action.
4. Press the return key again.

NOTE: Active messages cannot be cleared.

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DEMONSTRATE
CLEARING LOGGED
DIAGNOSTIC EVENTS

Clearing Logged Events

Demonstrate Clearing The second category of diagnostic screens is "Logged Events," which
Logged Events provide information on engine abuse. The five categories of events are:

• Overspeed
• Air Filter Restriction
• Overheating
• Low Oil Pressure
• Engine Shutdown (No security)

Also recorded is the following information:

• Event description
• Number of occurrences
• ECM hour of first and last occurrences

Overspeeds are also logged as the "Engine Overspeed Histogram."

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SHOW
OVERSPEED
HISTOGRAM SCREEN

Engine Overspeed Histogram

Demonstrate Clearing
the Engine Overspeed The overspeed category is represented by a histogram indicating the
Histogram
highest speed attained, the number of overspeeds to this rpm, the last
occurrence, and the current hours.

The histogram is divided into five speed ranges:

2200, 2400, 2600, 2800 and 3000 rpm

NOTE: During an overspeed incident, only the highest rpm is logged

and only after the engine returns to normal speed. For example, the
engine runs from 1500 to 2900 rpm and returns to 1800 rpm. Only one
overspeed incident will be recorded (at 2800 rpm).

Events can only be cleared with two factory passwords, thus protecting
the information for investigative purposes.
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SHOW FACTORY
PASSWORD ENTRY
SCREEN

Demonstrate clearing Electronic Security Measures

events with a factory
password The "Total Tattletale" indicates how often a parameter has been changed.
It is also used to obtain a password.

The "Parameter Change History" indicates the serial number of the ECAP
used in setting changes.

Only engine Events are protected by factory passwords which are

obtained from the factory according to the instructions on the screen.

Follow the instructions shown on the screen to clear logged engine

Events.

The student materials contain a list of all the information necessary to

obtain factory passwords. The list can be duplicated to facilitate the
gathering and recording of the information.
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DEMONSTRATE
TIMING SENSOR
CALIBRATION

Timing Sensor Calibration

Demonstrate Timing The calibration procedure requires connecting the wiring harness 2 pin
Sensor Calibration DT plug (just below the ECM) to the magnetic pickup positioned in the
flywheel housing.

The timing calibration procedure is initiated by an ECAP service tool key

stroke.

During the automatic process, the engine will automatically increase to

800 rpm and the injection timing circuit will be calibrated by the ECM.

Step through the screens until the ECAP reports that the system is
calibrated.

NOTE: The pressure sensors do not require the ECAP for calibration.
This procedure can be performed by turning the key switch ON and
waiting five seconds before starting the engine.
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SHOW
DIAGNOSTIC TEST
SCREENS

Diagnostic Tests
Demonstrate the The three diagnostic screens are:
Diagnostic Tests
Screens
1. Cylinder Cutout/Injection Duration
2. Injector Solenoid Test
3. Parameter Override Tests
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DEMONSTRATE
CYLINDER CUTOUT

Cylinder Cutout
Demonstrate the This test is used to identify a problem with a cylinder which is either low
Cylinder Cutout on power or totally "dead."

Any number of cylinders can be cut out with the engine running to isolate
a problem cylinder. Depending on the magnitude of the load, rpm will
decrease or injector duration will increase when a good cylinder is cut
out. When a defective (dead) cylinder is cut out, no difference will be
detected.
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DEMONSTRATE
INJECTOR SOLENOID
TEST

Injector Solenoid Test

Demonstrate the This test is used to determine whether or not a cylinder problem is in the
Injector Solenoid Test electrical circuit.

With the engine stopped, the solenoids will be activated in turn. A

defective injector solenoid can be diagnosed both by sound and by
viewing the ECAP screen. All the solenoids will emit a distinct "click."
Individual cylinders can be checked with the return key.
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DEMONSTRATE
OVERRIDE
PARAMETERS

Override Parameters
Demonstrate the With this screen, the warning lights and buzzers can be switched on and
Override Parameters off for diagnostic purposes.
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SYSTEM
DIAGNOSTICS LAB
WITH TRAINING AID
AND ECAP

Introduce and perform Lab E - System Diagnostics with Training Aid and ECAP
Lab E
This classroom exercise will reinforce the material covered in the
Summarize lab by
asking questions preceding presentation.
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ENGINE DIAGNOSTICS
LAB WITH ECAP

Introduce and perform Lab F - Engine Diagnostics with ECAP

Lab F
This classroom exercise will also reinforce the material covered in the
Summarize lab by
assign questions preceding presentation.