G3516 Generator Set CSZ00001-UP(SEBP3374 - 29) - Document Structure Page 1 of 5
Shutdown SIS
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Product: GENERATOR SET
Model: G3516 GENERATOR SET CSZ
Configuration: G3516 Generator Set CSZ00001-UP
Troubleshooting
G3500 Engines
Media Number -SENR6413-08 Publication Date -01/06/2008 Date Updated -05/06/2008
i01920931
System Overview
SMCS - 1900
Introduction
Electronic Ignition System (EIS)
The Caterpillar EIS provides variable ignition timing that is sensitive to detonation. The EIS consists of
the following components:
z EIS control module
z Ignition transformers
z Speed/Timing sensor
z Manifold air pressure sensor (MAP)
z Detonation sensors
Each cylinder has an ignition transformer that is located under the valve cover for the cylinder. To
initiate combustion, the control module sends a pulse of approximately 190 volts to the primary coil of
each ignition transformer at the appropriate time and for the appropriate duration. The transformers step
up the voltage in order to create a spark across the spark plug electrode.
Detonation sensors monitor the engine for excessive detonation. The engine has two detonation sensors.
Each sensor monitors one cylinder bank. The sensors generate data on vibration that is processed by the
control module in order to determine detonation levels. If detonation reaches an unacceptable level, the
control module retards the ignition timing of the cylinders. If retarding the timing does not limit
detonation to an acceptable level, the control module shuts down the engine.
The ignition is enabled via an input on the control module. The input is activated by a control system
that is provided by Caterpillar or by the customer.
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The control module provides extensive diagnostics for the ignition system. The control module also
contains an input for ignition timing in order to allow operation with alternate fuels such as propane that
require a timing offset.
Optional Electronic Systems
Optional electronic systems provide additional capabilities and features. The systems that may be
installed depend on the application.
z Air/fuel ratio control
z Status Control Module (SCM)
z Other systems that are provided by Caterpillar or by the customer
Air/Fuel Ratio Control
The engine may be equipped with an air/fuel ratio control system. The system provides the following
capabilities:
z Control of exhaust emissions
z Adjustment for changes in the fuel BTU
z Engine speed governing
The system consists of the following components:
z Electronic Control Module (ECM)
z Oxygen sensor
z Oxygen buffer
z Speed sensor
z Inlet manifold pressure sensor
z Inlet manifold temperature sensor
z Fuel valve
z Throttle actuator
z Input switches
Some of the components are located in a remote control panel that is connected to the engine via a
wiring harness.
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The air/fuel ratio control consists of two subsystems: air/fuel ratio control and engine speed governing.
Air/Fuel Ratio Control
The ECM provides control of the air/fuel mixture for performance and efficiency at low emission levels.
The control compensates for changes in the BTU of the fuel in order to maintain desired emission levels.
The following steps describe the basic operation:
1. The ECM determines the desired flow rates for the air and the fuel. The flow rates are determined
by these factors:
{ Desired engine speed
{ Actual engine speed
{ Calculated engine load
2. The ECM sends a signal to the fuel metering valve and a signal to the governor.
3. The ECM monitors the amount of oxygen in the exhaust gas via the oxygen sensor. The ECM
adjusts the signal for the flow of air and fuel in order to achieve the desired level of exhaust
emissions.
This process is repeated continuously during engine operation unless the AFR control has been disabled.
The air/fuel ratio control may be disabled with the Digital Diagnostic Tool (DDT). This aids in
troubleshooting the system.
The air/fuel ratio control communicates with the EIS via the Cat data link. Sensor information and
control information are passed between the two systems via the Cat data link.
Engine Speed Governing
The ECM uses sensors, switches, and the throttle actuator in order to govern the speed of the engine.
Desired engine speed is determined by the status of the idle/rated switch, the desired speed input, and
programmable parameters.
The source of the desired engine speed depends on the application. The input may be from a
potentiometer, a pressure module, or an electronic device.
Inside the ECM, the desired engine speed is compared to the actual engine speed. The ECM uses gains
in order to provide stable operation. The ECM issues a throttle command to the throttle actuator.
The throttle actuator is electrically controlled and hydraulically actuated. The throttle position is
controlled in open loop mode: there is no feedback for the throttle position. The actual throttle position
can be viewed on a mechanical pointer that is built into the mechanism of the throttle.
Status Control Module (SCM)
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The SCM includes the following features:
z Control of starting the engine and stopping the engine
z Basic engine protection
z A display of the status of certain parameters
z Shutdown indicators
z Diagnostic information
When the SCM receives a signal to start the engine, the SCM activates the fuel system and the starting
motor. The SCM also sends a command to the EIS control module in order to begin the ignition. When
the engine rpm reaches the crank termination speed, the starting motor is disengaged.
The SCM will sequentially display the following parameters in two second increments: service hours,
engine rpm, battery voltage, engine oil pressure and engine oil temperature. The SCM also monitors the
engine for faults.
The SCM protects the engine from certain faults. For example, the SCM will shut down the engine if the
oil temperature is above the setpoint.
The SCM displays certain operating parameters. For example, the temperature of the oil can be
displayed on the module's indicator.
The SCM also has light emitting diodes that indicate an engine shutdown.
The engine will operate until the SCM receives a shutdown signal. The shutdown signal can come from
a switch or from the EIS control module. When the SCM shuts off the fuel supply, the SCM also sends a
command to the EIS control module in order to terminate the ignition.
Engine Monitoring and Protection
The engine may be equipped with a system that provides additional features. The system that is installed
depends on the application. The system may communicate with the EIS and the air/fuel ratio control via
the Cat data link. The system may provide some of the following features or all of the following
features:
z Control of starting the engine and stopping the engine
z Basic engine protection
z A display of the status of certain operating parameters
z Diagnostic information
These features may be provided by these systems:
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z Status Control Module
z Electronic Modular Control Panel (EMCP)
Start/Stop Control
If the system provides start/stop control of the engine, the system sends a command to the EIS control
module. The command enables the ignition and the command disables the ignition.
If the system does not provide start/stop control of the engine, the starting of the engine and the stopping
of the engine is controlled by equipment that is provided by the customer.
Basic Engine Protection
The system may provide additional protection for the engine. The protection that is provided depends on
the system. For example, protection may be provided for the loss of oil pressure.
Engine Operating Parameters
The system may provide indications of engine operation. For example, the system may provide a digital
indication of the oil pressure and the oil temperature.
Diagnostic Information
The system may provide additional diagnostic information for the engine. For example, if the engine
was shut down for high oil temperature, the system would provide a diagnostic code for the event.
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