Systems Operation  Section

KENR8772

Communication Adapter  Tool  –  The

communication adapter provides a communication

link between the ECM and the Electronic  Service

Tool.

Engine Control Module (ECM)  – The ECM is the

control computer of the engine. The ECM provides

power to the electronics. The ECM monitors data that

is input from the sensors of the engine.  The ECM

acts as a governor in order to control the speed and

the power of the engine.

Component Identifier (CID)  – The CID is a number

that identifies the specific component of the electronic

control system that has experienced a diagnostic

code.

Electronic Service Tool   – The electronic service

tool is used for diagnosing various electronic controls.

Coolant Temperature Sensor  – The coolant

temperature sensor detects the  engine coolant

temperature for all normal operating conditions and

for engine monitoring.

Engine Monitoring  – Engine Monitoring is the part

of the electronic engine control that monitors  the

sensors. This also warns the operator of detected

problems.

Customer Specified Parameters  – A customer

specified parameter is a  parameter that can be

changed in the ECM with the Electronic Service Tool.

A customer specified parameter's value is  set by

the customer. These parameters are protected by

customer passwords.

Engine Oil Pressure Sensor  – The engine oil

pressure sensor measures engine oil pressure. The

sensor sends an electronic signal to the ECM that is

dependent on the engine oil pressure.

Engine Speed/Timing Sensor  – An  engine

speed/timing sensor is a Hall effect sensor. The ECM

interprets this signal as the crankshaft position and

the engine speed. Two sensors are used to provide

the speed and timing signals to the ECM. The primary

sensor is associated with the crankshaft  and the

secondary sensor is associated with the camshaft.

Data Link – The Data Link is used for communication

with other microprocessor-based devices.

Derate  – Certain engine conditions will generate

event codes. Also, engine derates may be applied.

The map for the engine derate is programmed into

the ECM software. The derate can be one or more

of three types: reduction of rated power, reduction of

rated engine speed, and reduction of rated machine

speed for OEM products.

Estimated Dynamic Timing  – Estimated dynamic

timing is the estimate of the actual injection timing

that is calculated by the ECM.

Event Code  – An event code may be  activated

in order to indicate an abnormal engine operating

condition. These codes usually indicate a mechanical

problem instead of an electrical system problem.

Desired Engine Speed  – The desired engine speed

is input to the electronic governor within the ECM.

The electronic governor uses the signal  from the

throttle position sensor, the engine  speed/timing

sensor, and other sensors in order to determine the

desired engine speed.

Failure Mode Identifier (FMI)  – This identifier

indicates the type of failure that is associated with

the component. The FMI has been adopted from the

SAE practice of J1587 diagnostics. The FMI follows

the parameter identifier (PID) in the descriptions of

the fault code. The descriptions of the FMIs are in

the following list.

Diagnostic Trouble Code  – A diagnostic trouble

code is sometimes referred to as a fault code. These

codes indicate an electronic system malfunction.

Diagnostic Lamp  – A diagnostic lamp is sometimes

called the check engine light. The diagnostic lamp

is used to warn the operator of the presence of an

active diagnostic code. The diagnostic lamps are

red and orange. The lamp may not be  included in

all applications.

0  – The data is valid but the data is above the normal

operational range.

1  – The data is valid but the data is below the normal

operational range.

Direct Current (DC)  – Direct current is the type of

current that flows consistently in only one direction.

2  – The data is erratic, intermittent, or incorrect.

3  – The voltage is above normal or the voltage is

Duty Cycle  – See Pulse Width Modulation.

shorted high.

Electronic Engine Control  – The  electronic

engine control is a  complete electronic system.

The electronic engine control monitors the engine

operation under all conditions. The electronic engine

control also controls the engine operation under all

conditions.

4  – The voltage is below normal or the voltage is

shorted low.

5  – The current is below normal or the circuit is open.

6  – The current is above normal or the  circuit is

grounded.

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KENR8772

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Systems Operation  Section

7  – The mechanical system is  not responding

properly.

Intake Manifold Pressure Sensor  – The Intake

Manifold Pressure Sensor measures the pressure

in the intake manifold. The pressure in the  intake

manifold may be different to the pressure  outside

the engine (atmospheric pressure). The difference

in pressure may be caused  by an increase in air

pressure by a turbocharger (if equipped).

8  – There is an abnormal frequency, an abnormal

pulse width, or an abnormal time period.

9  – There has been an abnormal update.

10  – There is an abnormal rate of change.

11  – The failure mode is not identifiable.

12  – The device or the component is damaged.

J1939 CAN Data Link  – Logged diagnostic codes

are codes which are stored in the memory. These

codes are meant to  be an indicator of possible

causes for intermittent  problems. Refer to the

term “Diagnostic Code” in this glossary  for more

information.

Flash File  – This file is  software that is inside

the ECM. The  file contains all the instructions

(software) for the ECM and  the file contains the

performance maps for a specific engine. The file may

be reprogrammed through flash programming.

NOx Reduction System  – The NOx Reduction

System recycles a portion of the exhaust gases back

into the inlet air in order to reduce the formation of

oxides of nitrogen (NOx) in the combustion process.

The recycled exhaust gas passes through a cooler

before being introduced into the inlet air.

Flash Programming  – Flash programming is the

method of programming or updating an ECM with an

electronic service tool over the data link.

OEM  – OEM is an abbreviation for the  Original

Equipment Manufacturer. This is the manufacturer of

the machine or the vehicle that uses the engine.

Flash Memory  – See Programmable Software.

Fuel Ratio Control (FRC)  – The FRC is a limit that

is based on the control of the fuel to the air ratio. The

FRC is used for emission control. When the  ECM

senses a higher turbocharger outlet pressure, the

ECM increases the limit for the FRC in order to allow

more fuel into the cylinders.

Open Circuit  – An open circuit is a condition that is

caused by an open switch, or by an electrical wire

or a connection that is broken. When this condition

exists, the signal or the supply voltage can no longer

reach the intended destination.

Parameter  – A parameter is a value or a limit that

is programmable. This helps  determine specific

characteristics or behaviors of the engine.

Fuel Pump  – See “Fuel Injection Pump”.

Fuel Injection Pump  – This item is sometimes

referred to as the Fuel Pump. This is a device that

supplies fuel under pressure to the injectors.

Parameter Identifier (PID)  – A PID is a numerical

code that contains two  digits or three digits. A

numerical code is assigned to each component. The

numerical code identifies data via the data link to the

ECM.

Harness  – The harness is the bundle of  wiring

(loom) that connects all components of the electronic

system.

Password  – A password is a group of  numeric

characters or a group of alphanumeric characters

that is designed to restrict access to parameters. The

electronic system requires correct passwords in order

to change some parameters (Factory Passwords).

Refer to Troubleshooting, “Factory Passwords” for

more information.

Hertz (Hz)  – Hertz is the measure of frequency in

cycles per second.

Inlet Manifold Air Temperature Sensor  –  The

inlet manifold air temperature sensor detects the

air temperature in the  inlet manifold. The ECM

monitors the air temperature and other data in the

inlet manifold in order to adjust injection timing and

other performance functions.

Programmable Software  – The software  is

programmed into the ECM. The software contains

all the instructions (software) for the ECM and the

software contains the performance  maps for a

specific engine. The software may be reprogrammed

through flash programming.

Integrated Electronic Controls  – The engine is

designed with the electronic controls as a necessary

part of the system.  The engine will not operate

without the electronic controls.

Power Cycling  – Power cycling refers to the action

of cycling the keyswitch from any position to the OFF

position, and to the START/RUN position.

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KENR8772

Systems Operation  Section

Primary Speed/Timing Sensor  – This sensor

determines the position of the  crankshaft during

engine operation. If  the primary speed/timing

sensor fails during engine operation, the secondary

speed/timing sensor is used to provide the signal.

Short Circuit  – A short circuit is a condition that has

an electrical circuit that is inadvertently connected to

an undesirable point. An example of a short circuit

is a wire which rubs against  a vehicle frame and

this rubbing eventually wears off the wire insulation.

Electrical contact with the frame is made and a short

circuit results.

Pulse Width Modulation (PWM)  – The PWM is a

signal that consists of pulses that  are of variable

width. These pulses occur at fixed intervals. The ratio

of “TIME ON” versus total “TIME OFF” can be varied.

This ratio is also referred to as a duty cycle.

Signal  – The signal is a voltage or a waveform that

is used in order to transmit information typically from

a sensor to the ECM.

Supply Voltage – The supply voltage is a continuous

voltage that is supplied to a component in order to

provide the electrical power that is required for the

component to operate. The power may be generated

by the ECM or the power may be battery voltage that

is supplied by the engine wiring.

System Configuration Parameters  –  System

configuration parameters are parameters that affect

emissions and/or operating characteristics of the

engine.

“T” Harness  – This harness is a test harness that

is designed to permit normal circuit operation and

the measurement of the voltage  simultaneously.

Typically, the harness is inserted between the two

ends of a connector.

g00284479

Illustration 4

Rated Fuel Limit  – This is a limit that is based on

the power rating of the engine and on the engine rpm.

The Rated Fuel Limit enables the engine power and

torque outputs to conform to the power and torque

curves of a specific engine model. These limits are in

the flash file and these limits cannot be changed.

Throttle Position  – The throttle position is  the

interpretation by the ECM of  the signal from the

throttle position sensor or the throttle switch.

Throttle Position Sensor  – The throttle position

sensor is an electronic sensor that is connected to an

accelerator pedal or a hand lever. This sensor sends

a signal to the ECM that is used to calculate desired

engine speed.

Reference Voltage  – Reference voltage is  a

regulated voltage and a  steady voltage that is

supplied by the ECM to  a sensor. The reference

voltage is used by the sensor to generate a signal

voltage.

Timing Calibration  – The timing calibration is the

adjustment of an electrical signal. This adjustment is

made in order to correct the timing error between the

camshaft and the engine speed/timing sensors or

between the crankshaft and the engine speed/timing

sensors.

Relay  – A relay is an electromechanical switch. A

flow of electricity in one circuit is used to control the

flow of electricity in another circuit. A small current or

voltage is applied to a relay in order to switch a much

larger current or voltage.

Secondary Speed/Timing Sensor  – This sensor

determines the position of the camshaft during engine

operation. If the primary speed/timing sensor fails

during engine operation, the secondary speed/timing

sensor is used to provide the signal.

Top Center Position – The top center position refers

to the crankshaft position when the engine  piston

position is at the highest point of travel. The engine

must be turned in the normal direction of rotation in

order to reach this point.

Sensor  – A sensor is used to detect a change in

the pressure, in the temperature, or in mechanical

movement. When any of these changes are detected,

a sensor converts the change into an electrical signal.

Total Tattletale  – The total tattletale is the total

number of changes to all the parameters that  are

stored in the ECM.

Wait To Start Lamp  – This is a lamp that is included

in the cold starting aid circuit in order to indicate when

the wait to start period has expired. The grid heater

has not deactivated at this point in time.

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KENR8772

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Systems Operation  Section

Wastegate  – This is a device in a turbocharged

engine that controls the maximum boost pressure

that is provided to the inlet manifold.

i04112658

Electronic Control System

Components

Introduction

The 1600 Series industrial engine is designed  for

electronic control. The engine has  an Electronic

Control Module (ECM), a high-pressure oil pump

and electronic unit injectors. All of these items are

electronically controlled. There are also a number

of engine sensors. The ECM controls  the engine

operating parameters through the software within

the ECM and the inputs from the various sensors.

The software contains parameters that control the

engine operation. The parameters include all of the

operating maps and customer-selected parameters.

The electronic control system has  the following

components:

•  ECM

•  Pressure sensors

•  Temperature sensors

•  Crankshaft position sensor

•  Camshaft position sensor

•  Electronic unit injectors

•  Valve for the NOx Reduction System  (NRS) (if

equipped)

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KENR8772

Systems Operation  Section

g02734078

Illustration 5

Typical example

(1) Exhaust cooler for the NOx Reduction

System (NRS) (if equipped)

(2) Valve for the  NOx Reduction System

(NRS) (if equipped)

(9) Exhaust backpressure sensor (EBP)

(10) Engine coolant temperature  sensor

(ECT)

(11) Crankshaft position sensor (CKP)

(12) Engine

(19) Fuel strainer

(20) Injection control pressure sensor (ICP)

(21) Engine oil pressure sensor (EOP)

(22) Electronic control module (ECM)

(23) High-pressure oil pump

(3) Muffler

(4) Air cleaner

(5) Inlet air temperature sensor (IAT)

(6) Turbocharger

(7) Exhaust gas valve for the NOx Reduction

System (NRS) (if equipped)

(8) Charge air cooler (CAC)

(13) Electronic unit injectors

(14) Low-pressure fuel pump

(15) Engine fuel pressure sensor (EFP)

(16) Inlet air heater control (IAHC)

(17) Camshaft position sensor (CMP)

(18) Fuel filter

(24) Injector drive module (IDM)

(25) Manifold air temperature sensor (MAT)

(26) Manifold air pressure sensor (MAP)

(27) Fuel tank

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.

This document is printed from SPI². Not for RESALE

KENR8772

13

Systems Operation  Section

g02974017

Illustration 6

Typical example

(1) Valve for the  NOx Reduction System

(NRS)

(2) Inlet air temperature sensor

(3) Inlet manifold air pressure sensor

(4) Water in fuel sensor

(5) Engine oil temperature sensor

(6) Injection pressure regulator

(7) Engine fuel pressure sensor

(8) Air inlet heater

(10) Crankshaft position sensor

(11) Coolant jacket heater

(12) Engine oil pressure sensor

(9) Control module

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KENR8772

Systems Operation  Section

g02976178

Illustration 7

Typical example

(13) Injection control  pressure sensor

(internal)

(14) Exhaust back pressure sensor

(15) Engine coolant temperature sensor

(16) Camshaft position sensor

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KENR8772

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Systems Operation  Section

g02732035

Illustration 8

Typical example

(1) Valve for the  NOx Reduction System

(NRS)

(2) Inlet air temperature sensor

(3) Inlet manifold air pressure sensor

(4) Water in fuel sensor

(5) Engine oil temperature sensor

(6) Injection pressure regulator

(7) Engine fuel pressure sensor

(8) Air inlet heater