Electronic Engine Control System - EUI

In an EUI engine the fuel delivery and injection timing are electronically controlled. In comparison to
engines that are controlled mechanically, the electronic control system provides increased control of
timing and increased control of the fuel to air ratio. Injection timing is achieved by precise control of
injector firing time, and engine power is controlled by adjusting the firing duration.

The ECM energizes the fuel injection solenoid in order to start the injection of fuel. The ECM will de-
energize the fuel injection solenoid in order to stop the injection of fuel.

The Caterpillar electronic engine control system-EUI consists of three major categories:

Control - example Engine Control Module (ECM)

Inputs - example sensors

Outputs - example actuators

It is important to understand that the control category consists of the ECM, personality module,
parameters, and data links. The major component in the control category is the ECM.

The Engine Control Module (ECM) is the computer that controls the engine. The ECM provides electrical
power for all engine mounted sensors and actuators. The ECM contains memory in order to store
customer specified parameters. The ECM is programmed to run diagnostic tests in order to separate a
fault to a specific circuit.

The ECM controls engine operation by monitoring inputs from the sensors, processing the information,
and then providing correct outputs to ensure desired engine operation. In comparison to engines that
are controlled mechanically, the fuel delivery and injection timing are electronically controlled. The
electronic control system provides increased control of timing and increased control of the fuel to air
ratio. Injection timing is achieved by precise control of injector firing time, and engine power is
controlled by adjusting the firing duration. The ECM energizes the fuel injection solenoid in order to
start the injection of fuel. The ECM will de-energize the fuel injection solenoid in order to stop the
injection of fuel.
 An input component is one that sends an electrical signal to the ECM. The signal that is
sent varies in either voltage or in frequency when there is a change in some specific system of the
engine. An example would be the engine speed / timing sensors or the atmospheric pressure sensor.
The ECM sees the input sensor signal as information about the condition, environment, or operation of
the engine.

The ECM receives the input signals. Electronic circuits that are inside the ECM evaluate the signals. The
ECM then supplies electrical energy to the output components of the system, which are in response to
predetermined combinations of input signal values.

Inputs can be sensors, switches, and data links. Sensors can measure pressure, temperature, fluid level,
position, and speed.
The ECM receives the input signals. Electronic circuits that are inside the ECM evaluate the signals. The
ECM then supplies electrical energy to the output components of the system, which are in response to
predetermined combinations of input signal values.

An output component is one that is operated by the ECM. An output component receives electrical
energy from the ECM. The electrical energy is used to perform one of the following functions:

Perform work. An example would be moving an injector solenoid plunger. An output component takes
an active part in regulating or operating the engine.

An output component can give information or a warning. An example would be a light or an alarm to the
operator of the engine.

Output components provide the ability to electronically control the engine operation in order to
improve the performance, fuel consumption rate, and reduced emissions levels.
Injector solenoids are the most common output. The ECM energizes the fuel injection solenoid in order
to start the injection of fuel. The ECM will de-energize the fuel injection solenoid in order to stop the
injection of fuel.

Injector components, operation, diagnosis and service will be covered in depth in the upcoming course
topics.
A troubleshooting chart helps create your list of possible causes based on symptoms that you may have
identified while verifying the customer concern and conducting an initial inspection.

NOTE: The intent of the troubleshooting chart is to teach diagnostic principles and not teach you all
possible symptoms nor encourage you to jump to conclusions. For additional troubleshooting details,
see current service information.
Performing an external visual inspection of the electronic engine control system occurs during the initial
inspection, after you have verified the customer concern.

Any of the following symptoms would lead you to externally inspect the electronic engine control
system:

Active or logged faults or events

Low power

Rough running

Misfire

Physical damage to components, wiring, or harnesses

Diagnosing the electronic engine control system using a DMM occurs while you are analyzing possible
causes and determining root cause.

Any of the following symptoms may lead you to diagnose the electronic engine control system using a
DMM:

Active or logged faults or events

Low power

Rough running

Misfire

Prior to using a DMM you should:

Test DMM against known voltage source

Calibrate DMM

Ensure connectors and grounds are secure and clean

Purpose of DMM Test

The operation of an electronic engine control system involves electrical inputs and outputs. The DMM
should be used to test sensors and circuits for electrical open and shorts. Additionally, the DMM may be
used to measure voltage or continuity at the sensor and ECM terminals.
Overview of the Diagnostic Procedure

The DMM test involves:

Setup:

Check with service information for specifications

Set the meter for testing - typically volts or ohms

Procedure: Use the meter to measure voltage and continuity by placing the leads in the appropriate
terminals.

Results and Next Steps

What to look for:

If results show no voltage, then check power input such as fuses and repair.

If results show poor ground, then clean and repair ground.

Diagnosing the electronic engine control system using Cat ET occurs while you are analyzing possible
causes and determining root cause.

Any of the following symptoms may lead you to diagnose the electronic engine control system using Cat
ET:

Active or logged faults or events

Low power

Rough running

Misfire

Cranks will not start

Prior to using Cat ET you should look for obvious issues such as fuses, battery condition, and loose
electrical connectors.
Cat ET communicates with the Engine Control Modules (ECMs) to:

View and clear diagnostics

View events

Perform diagnostic tests

Perform calibrations

Print reports and diagnostic results

Program ECM software-flash files, injector trim codes, and injector trim files

Diagnose communication errors

Caterpillar Service Information System (SIS) contains information that includes:

Parts manuals

Service manuals

Schematics

Tooling

Service software files

Flash file search performs the following functions:

Locates latest ECM flash files

Locates injector trim files

Locates serial numbers

Locates by flash file number

Links to WinFlash
 Listed are the key components related to the operation of the EUI.

The solenoid (1) is an electrical component used by the ECM to control the poppet valve.

The cartridge valve assembly (2) is driven by the solenoid and controls fuel flow.

Driven by the rocker arm, the tappet (3) transfers force to the plunger.

Driven by the tappet, the plunger (4) pressurizes fuel in the barrel.

The barrel (5) contains fuel to be pressurized by the force of the plunger.

The nozzle check (6) valve prevents fuel from injecting into the cylinder until a minimum fuel
pressure is reached.
Performing an external visual inspection for the electronic unit injector occurs during the initial
inspection, after you have verified the customer concern.

Any of the following symptoms would lead you to externally inspect the EUI.

Active or logged faults or events

Low power

Rough running

Misfire

Prior to conducting the inspection, you should perform the following procedures:

Cylinder cutout test

Injector solenoid test

Remove the valve cover and look for broken parts. Repair or replace any broken parts that are found.
The screen identifies the key areas involved in an external visual inspection of the electronic unit
injector.

Inspect all wiring (1) for the solenoids.

Look for loose connections (2). Also look for frayed or broken wires. Ensure that the connector for the
unit injector solenoid is properly connected.

Perform a pull test (3) on each of the wires.

Inspect the solenoid posts (4) for signs of arcing. If signs of arcing are found, remove the cap assembly.
Clean the connecting posts.
Now that you have completed this course, you should be able to:

Identify the correct operation of the EUI electronic engine control system

Diagnose EUI electronic engine control system concerns using a systematic diagnostic process

Diagnose EUI electronic engine control system concerns procedures using a troubleshooting chart

Diagnose EUI electronic engine control system using visual inspections

Diagnose EUI electronic engine control system concerns using a Digital Multimeter (DMM)

Diagnose EUI electronic engine control system using Caterpillar Electronic Technician

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