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3126 Truck Engine 7LZ00001-UP(SEBP2797 - 07) - Estructura del docum... 29/09/2011 01:44:05 p.m.
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Producto: TRUCK ENGINE

Modelo: 3126 TRUCK ENGINE 7LZ
Configuracin: 3126 Truck Engine 7LZ00001-UP
Localizacin y Solucin de Problemas

3100 HEUI DIESEL TRUCK ENGINE
Nmero de medio -SENR6566-03 Fecha de publicacin -01/01/1998 Fecha de actualizacin -28/11/2007
SENR65660003
P-1.0 3100 HEUI Electronic System Overview

System Operation
The 3100 HEUI Diesel Truck Engines use a Hydraulic Electronic Unit Injector fuel system. The injection
pump, fuel lines and nozzles required for fuel injection in mechanical Caterpillar engines have been replaced
with a hydraulic electronic unit injector in each cylinder. Some mechanical drive components, cam lobes,
lifter, push rod, and rocker arms required for fuel injection in mechanical or Electronic Unit Injector
Caterpillar engines have been replaced with a high pressure oil system.
A solenoid on each injector controls the amount of fuel delivered by the injector. A gear-driven axial piston
pump raises the normal engine operating oil pressure to injector actuation pressure levels required by the
injectors. An Electronic Control Module (ECM) sends a signal to the injection actuation pressure control
valve to control injection pressure, and another signal to each injector solenoid to inject fuel.
Electronic Controls
The 3100 HEUI Diesel Truck Engines electronic system consists of the Electronic Control Module (ECM),
Engine Sensors, Injection Actuation Pressure Control Valve, and Vehicle Interface. The ECM is the
computer which controls the 3100 HEUI engine. The Personality Module in the ECM contains the software
which controls how the ECM behaves (the personality module stores the operating maps that define power
rating, torque curves, rpm, etc).
Engine Governor
The Electronic Control system on the 3100 HEUI engine serve as the engine governor. The Electronic
Control system determines when and how much fuel to deliver to the cylinders, as well as injection pressure
based on the actual and desired conditions at any given time during starting and operation.
Basic Governor
The basic governor operation considers the desired and actual conditions, and then takes action to best
accommodate the desired conditions.
The desired conditions are typically the position of the accelerator pedal, desired vehicle speed when in
cruise control, or desired engine rpm when in PTO control. The actual conditions are based on current
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operating conditions such as coolant temperature, load conditions, etc.
Timing Considerations
Once the ECM has determined how much fuel is required, it must next determine when to inject the fuel.
Injection timing is determined by the ECM after considering input from the coolant temperature sensor,
intake manifold air temperature sensor, and boost pressure sensor.
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The ECM knows the cylinder position for timing because of the signal from the Engine Speed/Timing
Sensors. The ECM adjusts timing for best engine performance, fuel economy and white smoke control.
Actual and Desired Timing cannot be viewed with an Electronic Service Tool.
The ECM knows where top center on cylinder #1 is from the signal provided by the engine Speed/Timing
Sensors. The ECM decides when injection should occur relative to top center and provides the signal to the
injector at the desired time.
Fuel Injection
The ECM controls the amount of fuel injected by varying signals to the injectors. The injectors will pump
fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to energize the solenoid.
The energized solenoid lifts the poppet off its seat, closing the oil path to drain and opening the inlet for the
high pressure oil. The high pressure oil enters the injector and acts on an intensifier piston, increasing the
pressure and injecting fuel. By controlling the timing and duration of the high voltage signal, the ECM can
control injection timing and the amount of fuel injected.
The ECM also controls the pressure of the fuel injected into the cylinder by controlling the injection
actuation pressure control valve. The injection actuation pressure control valve is a dump valve closely
controlling the output pressure of the high pressure oil pump.
The Personality Module inside the ECM sets certain limits on the amount of fuel that can be injected. FRC
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Fuel Pos is a limit based on boost pressure to control the air/fuel ratio for emissions control. When the ECM
senses a higher boost pressure (more air into cylinder), it increases the FRC Fuel Pos limit (allows more fuel
into cylinder).
Rated Fuel Pos is a limit based on the power rating of the engine and rpm. It is similar to the rack stops and
torque spring on a mechanically governed engine. It provides power and torque curves for a specific engine
family and rating. All of these limits are determined at the factory in the Personality Module and cannot be
changed in the field. Injection timing depends on engine rpm, load and other operating factors.
Injection Actuation Pressure System

The ECM controls fuel injection by controlling oil. The pressure of the oil in the high pressure oil manifold
is controlled by the ECM through control of the injection actuation pressure control valve. The injection
actuation pressure control valve (dump valve) controls the high pressure pump outlet pressure by dumping
excess flow back to the oil sump.
The ECM monitors the pressure in the high pressure manifold through the injection actuation pressure
sensor. The injection actuation pressure sensor is located in the top of the manifold on the left side of the
engine. The injection actuation pressure sensor signal (Inj Act Pr) is compared by the ECM to the desired
injection actuation pressure (Des Inj Act Pr). The ECM determines the Des Inj Act Pr based on several
inputs and changes the position of the injection actuation pressure control valve (Inj Act Output) to adjust
the oil pressure in the high pressure manifold.
High pressure oil is routed from the pump to the high pressure manifold through a steel tube. From the
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manifold the oil is routed to each injector through short jumper tubes. All injectors have a constant supply of
oil while the engine is running. Cutting out an injector disables the electrical signal to the injector solenoid,
but does not interrupt the oil flow to the injector.
Customer Parameters Affect on Engine Governing

A unique feature of Electronic Engines is Customer Specified Parameters. These parameters allow the truck
owner to instruct the ECM how to fine tune the engine operation to accommodate the typical usage of the
vehicle, and to match the power train of the vehicle.
Many of the Customer Parameters provide additional restrictions on the "Required Action" the ECM will
take in response to the drivers' input.
Some parameters are intended to notify the driver of potential engine damage (Engine Monitoring
Parameters). Some parameters enhance fuel economy (Vehicle Speed, Cruise Control, Engine/Gear Limits
and Idle Shutdown Parameters). Other parameters are provided to enhance the engine installation or provide
engine operation information to the truck owner.
Engine Monitoring
Caterpillar provides a factory installed Engine Monitoring system. The Caterpillar Engine Monitoring
system monitors engine coolant temperature. The coolant temperature sensor is standard on all engines.
Caterpillar Engine Monitoring can be programmed to three different modes (OFF, WARNING, or
DERATE) through a Customer Parameter. The Coolant Temperature Sensor will operate in the Engine
Monitoring Mode selected.
NOTE: Excessive Coolant Temperature will not shut down the engine.
Caterpillar Engine Monitoring OFF Operation

If Caterpillar Engine Monitoring is programmed to OFF, the control system ignores the coolant temperature
sensor if conditions are exceeded which could cause the ECM to take Engine Monitoring action.
The engine still uses the Coolant Temperature sensor for normal engine operation, such as for Cold Mode
operation.
Caterpillar Engine Monitoring WARNING Operation

If the system is programmed to WARNING, the ECM causes the Check Engine Lamp to Flash (because of
the Active Diagnostic Code) to indicate a problem has been detected by the Engine Monitoring System. The
diagnostic code is logged. No further ECM or engine action occurs if the ECM is programmed to
WARNING.
Caterpillar Engine Monitoring DERATE Operation
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Figure 1 - Engine Monitoring Coolant Temperature Graph
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If the system is programmed to DERATE, the ECM begins by flashing the Check Engine Lamp to indicate a
problem has been detected by the Engine Monitoring System. The diagnostic code is logged. The ECM
limits the maximum vehicle speed and reduces available power as shown below.
This derating of usual engine performance is provided to influence the drivers' attention so action can be
taken to avoid engine damage. The three graphs above show the temperature derate trip points for the 3100
engines, and a rating for special applications.
Other ECM Performance Functions

The ECM also provides enhanced control of the engine for vehicle functions such as engine exhaust braking.
The illustration on page 13 shows many of the OEM systems the ECM can monitor to provide enhanced
vehicle performance, fuel economy and driver convenience.
Self-Diagnostics
The 3100 HEUI electronic system has some ability to diagnose itself. When a problem is detected, a
diagnostic code is generated and the Check Engine/Service Engine Soon lamp is turned ON. In most cases,
the code is also stored in permanent memory (Logged) in the ECM.
When diagnostic codes occur, they are called Active. They indicate a problem of some kind currently exists.
They should always be serviced first. If a truck has an Active Code, find the code in the front of this manual
and proceed to the indicated page to diagnose the cause.
Diagnostic codes stored in memory are Logged. Since the problem may have been temporary or may have
been repaired since the time it was logged, logged codes do not necessarily mean something needs to be
repaired. They are instead meant to be an indicator of probable causes for intermittent problems.
Some of the codes require passwords to clear. Codes not requiring passwords to clear are automatically
deleted from memory after 50 ECM operating hours.
Diagnostic Codes Effect on Engine Performance

This manual contains a table listing all of the PID-FMI Diagnostic codes, along with the page number
where details regarding the cause, performance affect, and troubleshooting of the code can be located.
The table on "PA-12: Possible Performance Effect of Active Diagnostic Codes" on page 46 lists all 3100
HEUI Diagnostic Codes, and whether each code may or may not affect engine performance.
The discussion on Engine Monitoring mentions the Check Engine Lamp flashes when a specific condition
exists. When the ECM detects the engine problem, it generates an Active Diagnostic Code and also Logs the
code to indicate when, and if appropriate, how many times the problem occurs. There are two types of
Diagnostic Codes, Fault Codes and Event Codes.
Diagnostic Fault Codes are provided to indicate an electrical or electronic problem has been detected by the
ECM. In some cases the engine performance can be affected when the condition causing the code exists.
More frequently, however, the driver cannot detect any difference in the engine performance.
If the driver indicates a performance problem occurs whenever the Check Engine Lamp is flashing, one of
the Diagnostic Codes may be the cause of the problem, and should be corrected.
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If the driver does not indicate a problem with the engine performance and a Diagnostic Code is logged by the
ECM, it indicates the ECM detected an abnormal condition, but it did not affect performance.
If this is the case, unless there are several occurrences of the specific diagnostic code in a very short period
of time, or the ECM is indicating the problem exists at the present time, there is most likely nothing wrong
with the electronic system.
Diagnostic Event Codes are provided to indicate operational problem has been detected in the engine (or
truck) by the ECM. This usually does not indicate an electronic malfunction. Event codes typically are not an
indication of an electronic system problem.
Lifetime Totals Stored In The ECM

The ECM maintains engine total data for the following parameters.
Engine Hours is engine running hours (it does not include time when the ECM is powered ON without the
engine running).
Distance data requires a vehicle speed sensor connected to the ECM (the same sensor used for ECM vehicle
speed).
PTO Hours and PTO Fuel are logged when engine rpm is set using the Cruise Control switches and the
engine is operating under some load, or when the Dedicated PTO On/Off Switch is ON and vehicle speed is
within range of the Idle/PTO Vehicle Speed Limit Parameter.
Idle Hours and Idle Fuel can include time when the engine speed is set using the Cruise switches and the
vehicle speed is within range of the Idle/PTO Vehicle Speed Limit Parameter, but the engine is not operating
under load.
Maintenance Indicator Data

The ECM records the Lifetime Data Totals when a maintenance reset occurs for three levels of maintenance
- PM1, PM2, and Coolant Flush/Fill. The previous maintenance point is used by the ECM to calculate when
the next maintenance is due.
The Maintenance Indicator feature is programmable to hours or distance. The PM1 maintenance is
programmable to OFF, Automatic-Distance, Automatic-Hours, Manual-Distance, or Manual-Hours.
If PM1 is programmed to Automatic (Distance or Hours), the ECM calculates the next maintenance due by
considering the vehicle operation history from the previous maintenance interval. If the vehicle has a history
of poor fuel economy, the maintenance indicator will occur sooner than a vehicle with better fuel economy.
The ECM also uses the Engine Oil Capacity, with a larger capacity providing a longer maintenance interval.
Engine Oil Capacity is programmed in quarts. If the PM1 Maintenance Indicator is programmed to Manual,
the owner can program in their own specific maintenance mileage or time interval. PM2 and Coolant
Flush/Fill intervals are determined by the factory.
CAT ID
The Caterpillar Driver Information Display (CAT ID) is available to provide operating information to the
driver about the engine such as engine rpm, coolant temperature, boost pressure, etc, as well as engine
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diagnostic codes with the PID-FMI and a brief text description.
CAT ID will also allow changing/resetting of certain operating parameters if the ECM is programmed to
access these parameters as well as PM1 Reset and Theft Deterrent.
The Theft Deterrent feature allows the driver to input a four character password to shut the engine down
and/or prevent the engine from restarting until the four character password is successfully entered.
NOTE: For CAT ID to function properly an AUG96 or later Personality Module is required in the ECM.
The CAT ID must also have the EEPROM chip capable of supporting communication with 3100 HEUI
engines, software version 1.3 or later. The version number is displayed initially on powerup of CAT ID.
Programmable Parameters
Certain parameters that affect 3100 HEUI Diesel Truck Engine operation may be changed with electronic
service tools. The parameters are stored in the ECM, and are protected from unauthorized changes by
passwords. These parameters are either "System Configuration Parameters" or "Customer Parameters".
System Configuration Parameters are set at the factory and affect emissions or power ratings within a
family of engines. Factory Passwords must be obtained and used to change System Configuration
Parameters.
Customer Parameters are variable and can be used to affect cruise control, vehicle speed limits,
progressive shifting, rpm/power ratings within the limits set by the factory, Caterpillar Engine Monitoring,
and PTO operation. Customer Passwords are necessary to change Customer Specified Parameters.
Some parameters may affect engine operation in ways a driver does not expect. Without adequate training,
these parameters may lead to power or performance complaints, even when the engine is performing to
specification.
Read section "P-2.0 Programming Parameters" on page 24 for more details.
Passwords
"System Configuration Parameters" are protected by Factory Passwords. Factory passwords are calculated
on a computer system available only to Caterpillar dealers. Since factory passwords contain alphabetic
characters, only an ECAP or Caterpillar Electronic Technician may change System Configuration
Parameters. System Configuration Parameters affect power family or emissions.
"Customer Parameters" are protected by Customer Passwords. The customer passwords are programmed
by the customer.
See section "P-2.0 Programming Parameters" on page 24, for more details when passwords are needed and
how to obtain them.
3100 HEUI Sensor and Connector Locations
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VCADS Pro 10(27)

3100 HEUI Engine Harness Wiring Diagram - 3126
3100 HEUI Vehicle Harness Wiring Diagram - 3126
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3100 HEUI Engine Harness Wiring Diagram - 3116
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3100 HEUI Vehicle Harness Wiring Diagram - 3116
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3100 HEUI Component Diagram
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Electrical Connectors and Functions
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Electrical Connectors and Functions
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Service Tools
The Caterpillar Electronic Service Tools for the 3100 HEUI Electronic Control system are designed to help
the service technician analyze and locate faults or problems within the system. It is required to perform some
sensor calibrations electronically, and to read or change engine parameters. The Electronic Control Analyzer
Programmer (ECAP) tool has small plug-in modules, called Service Program Modules (SPM), to adapt the
basic tool to the specific Caterpillar electronic control application. Caterpillar Electronic Technician (ET)
requires a personal computer with the ET software installed and either a Caterpillar Communication Adapter
or MPSI Pro-Link with Caterpillar Cartridge to translate from the Vehicle ATA Data Link to the computer
RS-232 port.
Either the ECAP or ET communicates with the 3100 HEUI Electronic Control Module to read Diagnostic
Codes, to read the various sensor output signals such as engine rpm, or boost pressure, and controls
electronic calibration of the 3100 HEUI sensors through the ECM.
The ECAP (requires PWM adapter to measure at the sensor) can measure Pulse Width Modulated (PWM)
signals, such as the signal produced by the Throttle Position Sensor.
There are several adapter cables, breakout T cables, probes, etc, that are used with the service tools in order
to access measurements of signals. A heavy duty multimeter is suitable for making the necessary
measurements, a multimeter that is capable of measuring Duty Cycle may also be required. Other Special
Tools include those needed to measure pressure or temperature.
3100 HEUI Service Tools
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VCADS Pro 19(27)

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Optional 3100 HEUI Service Tools
VCADS Pro 22(27)

VCADS Pro 23(27)

VCADS Pro 24(27)

VCADS Pro 25(27)

Thu Sep 29 13:42:23 CDT 2011

Copyright 1993 - 2008 Caterpillar Inc.
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Todos los derechos reservados.

Red privada para licenciados del SIS.
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3126 Truck Engine 7LZ00001-UP(SEBP2797 - 07) - Estructura del docum... 29/09/2011 01:44:05 p.m.

Producto: TRUCK ENGINE

Localizacin y Solucin de Problemas

P-1.0 3100 HEUI Electronic System Overview

VCADS Pro 1(27)

operating conditions such as coolant temperature, load conditions, etc.

VCADS Pro 2(27)

VCADS Pro 3(27)

Injection Actuation Pressure System

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Customer Parameters Affect on Engine Governing

Caterpillar Engine Monitoring OFF Operation

Caterpillar Engine Monitoring WARNING Operation

Caterpillar Engine Monitoring DERATE Operation

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Figure 1 - Engine Monitoring Coolant Temperature Graph

Figure 2 - Engine Monitoring Coolant Temperature Graph

Figure 3 - Engine Monitoring Coolant Temperature Graph

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Other ECM Performance Functions

Diagnostic Codes Effect on Engine Performance

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Lifetime Totals Stored In The ECM

Maintenance Indicator Data

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diagnostic codes with the PID-FMI and a brief text description.

Read section "P-2.0 Programming Parameters" on page 24 for more details.

3100 HEUI Sensor and Connector Locations

VCADS Pro 9(27)

VCADS Pro 10(27)

3100 HEUI Engine Harness Wiring Diagram - 3126

3100 HEUI Vehicle Harness Wiring Diagram - 3126

VCADS Pro 11(27)

3100 HEUI Engine Harness Wiring Diagram - 3116

VCADS Pro 12(27)

3100 HEUI Vehicle Harness Wiring Diagram - 3116

VCADS Pro 13(27)

3100 HEUI Component Diagram

VCADS Pro 14(27)

Electrical Connectors and Functions

VCADS Pro 15(27)

Electrical Connectors and Functions

VCADS Pro 16(27)

VCADS Pro 17(27)

3100 HEUI Service Tools

VCADS Pro 18(27)

VCADS Pro 19(27)

VCADS Pro 20(27)

VCADS Pro 21(27)

Optional 3100 HEUI Service Tools

VCADS Pro 22(27)

VCADS Pro 23(27)

VCADS Pro 24(27)

VCADS Pro 25(27)

Thu Sep 29 13:42:23 CDT 2011

VCADS Pro 26(27)

Todos los derechos reservados.

VCADS Pro 27(27)

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