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Product: GAS ENGINE

Model: G3516 GAS ENGINE 4EK
Configuration: G3516 Engine Electronic Ignition System 4EK00001-UP
Systems Operation
G3500 Engines
Media Number -SENR6412-07 Publication Date -01/08/2005 Date Updated -29/08/2005
i02036503
Electronic Control System Operation

SMCS - 1900
Illustration 1 shows the main components of the electronic control system.
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Illustration 1 g00905966
Schematic of the electronic control system with air/fuel ratio control
(1) Remote Control Panel (Status)
(2) Electronic Control Module (ECM) in a remote panel
(3) Manifold air pressure sensor
(4) Engine speed sensor (magnetic pickup)
(5) EGP3 actuator
(6) Oxygen buffer
(7) Oxygen sensor
(8) Inlet manifold temperature sensor
(9) Actuator for the fuel valve
(10) Fuel valve
(11) Caterpillar Electronic Technician (Cat ET)
(12) Digital Diagnostic Tool (DDT)
(13) Engine speed/timing sensor
(14) Detonation sensor
(15) Engine mounted junction box
(16) EIS Control Module
(17) Ignition transformer
(18) Spark plug
Control panel (1) and ECM (2) are remotely mounted from the engine. The control panel enables the operator
to control engine operation. The Status Control Module (SCM) in the control panel and the ECM monitor
engine operation. The SCM and the ECM also display operating parameters and diagnostic codes. For
information on the monitoring system, refer to Systems Operation, "Engine Monitoring System".
The ECM uses manifold air pressure sensor (3) and engine speed sensor (4) to govern the engine speed with
actuator (5). For information on governing, refer to Systems Operation, "Governor".
The ECM uses manifold air pressure sensor (3), oxygen buffer (6), oxygen sensor (7), and inlet manifold
temperature sensor (8) to control the air/fuel ratio with actuator (9) and with fuel valve (10). For information
on the air/fuel ratio control, refer to Systems Operation, "Air/Fuel Ratio Control".
Note: If the engine has the air/fuel ratio control, the ECM sends information from the manifold air pressure
sensor to the EIS control module via the CAT Data Link. If the engine does not have the air/fuel ratio control,
the manifold air pressure sensor sends information directly to the EIS control module.
EIS control module (16) is mounted on the engine. The control module uses manifold air pressure sensor (3),
engine speed/timing sensor (13), and detonation sensor (14) for control of ignition through ignition
transformer (17) and through spark plug (18). For more information on the EIS control module, refer to
Systems Operation, "Ignition System".
The ECM and the EIS control module communicate via the CAT Data Link. Wiring harnesses are routed
through engine mounted junction box (15). Both the ECM and the EIS control module can be programmed for
individual installations. The Cat ET (11) or a DDT (12) is used for programming. Either electronic service
tool can be connected to the ECM or to the junction box. For information on the programmable parameters,
refer to Systems Operation, "Electronic Control System Parameters".
Engine Controls
The engine may be equipped with the following control panels for engine operation:
customer Supplied Control Panel
The customer is responsible for the fabrication of a control panel for the engine. The customer must provide
following controls for engines that are not equipped with a Caterpillar Control Panel:
Emergency stop button
Engine control switch
Engine speed control
Diagnostic reset switch
Power on indicator
Warning indicator
Shutdown indicator
Optional Remote Control Panel with Status Control Module
Controls on the remote control panel (status)
(1) "DIAGNOSTIC RESET" switch
(2) Engine control switch
(3) "EMERGENCY STOP" button
The customer is responsible for supplying a source of engine speed control for the engine.
"DIAGNOSTIC RESET" switch (1) is a toggle switch that is used to clear diagnostic codes from the EIS
control module. The switch cannot clear individual codes. Use of the switch will clear all codes that are active
in the ECM. Do not clear the codes until the problems that caused the codes are addressed.
Engine control switch (2) is used to control starting the engine and stopping the engine.
Engine Control Switch
The engine control switch is a rotary switch that has four positions:
Off/Reset
Automatic
Manual start
Cooldown/Stop
Note: Only the fault indicators on the status control module are reset when the engine control switch is turned
to the off/reset position. Diagnostic codes must be cleared with the "DIAGNOSTIC RESET" switch.
Off/Reset - When the engine control switch is turned to this position (12 o'clock), the fault indicators on the
status control module are reset and the engine shuts down immediately. The power to the ECM and to the
status control module is shut off. This method is not recommended for normal stopping.
Automatic - When the engine control switch is in this position (3 o'clock), the system is configured for
remote operation. When the remote start/stop initiate contact closes, the engine will start. When the remote
start/stop initiate contact opens, the engine will shut down. If the cooling cycle is programmed, the engine
will operate for the cooldown period before the engine stops.
Manual start - When the engine control switch is turned to this position (6 o'clock), the engine will start. The
engine will continue to operate when the switch is in this position.
Cooldown/Stop - This is the preferred method for normal stopping. When the engine control switch is turned
to this position (9 o'clock), the engine will continue to operate until a programmable cooling cycle has
elapsed. The cooling cycle can be programmed for a 0 to 30 minute period. The default setting is five
minutes.
NOTICE
Emergency shutoff controls are for EMERGENCY use ONLY. DO
NOT use emergency shutoff devices or controls for normal stopping
procedure.
"EMERGENCY STOP" button (3) is used to stop the engine in an emergency situation. When the button is
pressed, the status control module shuts off the fuel via the gas shutoff valve. The module also terminates the
ignition. The "EMERGENCY STOP" button must be reset before the engine will start.
NOTICE
Do not start the engine until the problem necessitating the emergency
stop has been located and corrected.
For further information, refer to Systems Operation/Testing and Adjusting, SENR6420, "Control Panel
(Status-Timing)".
Optional Remote Control Panel with Status Control Module and Air/Fuel Ratio Control
Controls on the remote control panel with status control module and with air/fuel ratio control
(1) "EMERGENCY STOP" button
(2) Engine control switch
(3) Switch for calibration of the oxygen sensor
(4) Speed potentiometer
(5) "IDLE/RATED" switch
Engine control switch (1) is used to control starting the engine and stopping the engine.
NOTICE
procedure.
Engine Control Switch
The engine control switch is a rotary switch that has four positions:
Off/Reset
Automatic
Manual start
Cooldown/Stop
Note: Only the fault indicators on the status control module are reset when the engine control switch is turned
to the off/reset position. Diagnostic codes must be cleared with the "DIAGNOSTIC RESET" switch.
Off/Reset - When the engine control switch is turned to this position (12 o'clock), the fault indicators on the
status control module are reset and the engine shuts down immediately. The power to the ECM and to the
status control module is shut off. This method is not recommended for normal stopping.
Automatic - When the engine control switch is in this position (3 o'clock), the system is configured for
remote operation. When the remote start/stop initiate contact closes, the engine will start. When the remote
start/stop initiate contact opens, the engine will shut down. If the cooling cycle is programmed, the engine
will operate for the cooldown period before the engine stops.
Manual start - When the engine control switch is turned to this position (6 o'clock), the engine will start. The
engine will continue to operate when the switch is in this position.
Cooldown/Stop - This is the preferred method for normal stopping. When the engine control switch is turned
to this position (9 o'clock), the engine will continue to operate until a programmable cooling cycle has
elapsed. The cooling cycle can be programmed for a 0 to 30 minute period. The default setting is five
minutes.
NOTICE
procedure.
"EMERGENCY STOP" button (2) is used to stop the engine in an emergency situation. When the button is
pressed, the status control module shuts off the fuel via the gas shutoff valve. The module also terminates the
ignition. The "EMERGENCY STOP" button must be reset before the engine will start.
NOTICE
Do not start the engine until the problem necessitating the emergency
stop has been located and corrected.
Switch (3) - This toggle switch is used for calibration of the oxygen sensor. The procedure must be performed
with the engine stopped. The Cat ET or the DDT can also be used to perform the procedure.
Speed potentiometer (4) - The speed potentiometer controls the engine speed. This rotary switch is activated
when the idle/rated switch is in the rated position. When you increase the engine rpm, the engine will
accelerate at the rate that is programmed into the ECM. The engine stops accelerating when the programmed
rated rpm is achieved.
IDLE/RATED switch (5) - When this toggle switch (5) is switched to the idle position, the engine operates
at the programmed low idle speed. The engine decelerates at the rate that is programmed into the ECM. When
idle/rated switch (5) is switched to the rated position, the speed potentiometer is activated.
"DIAGNOSTIC RESET" switch (6) - This toggle switch is used to clear diagnostic codes from the ECM.
The switch cannot clear individual codes. Use of the switch will clear all codes that are active in the ECM. Do
not clear the codes until the problems that caused the codes are addressed.
Optional Remote Control Panel with Air/Fuel Ratio Control Canadian Standard
Association (CSA)
The configuration for CSA may include a remote control panel that includes air/fuel ratio control.
The customer is responsible for supplying an engine control switch and a remote speed control for the engine.
Controls on the optional remote control panel with air/fuel ratio control for CSA
(1) "LOCAL HIGH" indicator
G3516 Engine Electronic Ignition System 4EK00001-UP(SEBP2185 - 64) - Docume... Página 10 de 12
(2) "LOCAL LOW" indicator
(3) Local speed potentiometer
(4) "LOCAL" indicator
(5) "REMOTE/LOCAL" switch
(6) "REMOTE" indicator
(7) "IDLE/RATED" switch
(8) Switch for calibration of the oxygen sensor
(9) "CIRCUIT BREAKER" reset
This panel has a Remote Speed Control (RSC).
The RSC allows the operator to select a local speed signal or a remote speed signal. The speed signals must
be within 2.5 percent of each other in order for the RSC to switch inputs.
During operation, the RSC illuminates these indicators:
"LOCAL LOW" (1) - The local speed is greater than 2.5 percent below the remote speed. The RSC will not
switch modes.
"LOCAL HIGH" (2) - The local speed is greater than 2.5 percent above the remote speed. The RSC will not
switch modes.
"LOCAL" (4) - The RSC is operating in the local mode. The desired speed signal is being provided by the
potentiometer.
"REMOTE" (6) - The RSC is operating in the remote mode. The desired speed signal is being provided by
the customer's equipment.
Local speed potentiometer (3) - The speed potentiometer controls the engine speed. This rotary switch is
activated when the idle/rated switch is in the rated position and when the remote/local switch is in the local
position. When you increase the engine rpm, the engine will accelerate at the rate that is programmed into the
ECM. The engine stops accelerating when the programmed rated rpm is achieved.
"LOCAL/REMOTE" switch (5) - This switch selects the location of the speed potentiometer for the engine.
When local/remote switch (5) is switched to the local position, the engine speed is controlled from the local
speed potentiometer (3). When this toggle switch (5) is switched to the remote position, the engine speed is
controlled from a remote speed potentiometer that is provided by the customer.
"IDLE/RATED" switch (7) - When idle/rated switch (7) is switched to the idle position, the engine operates
at the programmed low idle speed. The engine decelerates at the rate that is programmed into the ECM. When
idle/rated switch (7) is switched to the rated position, the speed potentiometer is activated.
Switch (8) - This toggle switch is used for calibration of the oxygen sensor. The procedure must be performed
with the engine stopped. The Cat ET or the DDT can also be used to perform the procedure.
"CIRCUIT BREAKER" reset (9) - This circuit breaker provides circuit protection for the air/fuel ratio
control.
Distribution Panel for CSA
Controls on the distribution panel for CSA
The customer is responsible for slipping an engine control switch. The customer is responsible for supplying a
source of engine speed control if the engine is not equipped with air/fuel ratio control.
"EMERGENCY STOP" button (1) - The emergency stop is used to stop the engine in an emergency
situation. When the button is pressed, the status control module shuts off the fuel via the gas shutoff valve.
The module also terminates the ignition. The "EMERGENCY STOP" button must be reset before the engine
will start.
"CIRCUIT BREAKER" reset - This circuit breaker provides circuit protection for the EIS control module.
Copyright 1993 - 2010 Caterpillar Inc. Mon Jul 19 17:11:45 UTC-0300 2010
All Rights Reserved.
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G3516 Engine Electronic Ignition System 4EK00001-UP(SEBP2185 - 64) - Document ...

Product: GAS ENGINE

Electronic Control System Operation

Illustration 1 shows the main components of the electronic control system.

Schematic of the electronic control system with air/fuel ratio control

(1) Remote Control Panel (Status)

(2) Electronic Control Module (ECM) in a remote panel

(3) Manifold air pressure sensor

(4) Engine speed sensor (magnetic pickup)

(5) EGP3 actuator

(6) Oxygen buffer

(7) Oxygen sensor

(8) Inlet manifold temperature sensor

(9) Actuator for the fuel valve

(10) Fuel valve

(11) Caterpillar Electronic Technician (Cat ET)

(12) Digital Diagnostic Tool (DDT)

(13) Engine speed/timing sensor

(14) Detonation sensor

(15) Engine mounted junction box

(16) EIS Control Module

(17) Ignition transformer

(18) Spark plug

customer Supplied Control Panel

Emergency stop button

Engine control switch

Engine speed control

Diagnostic reset switch

Optional Remote Control Panel with Status Control Module

(1) "DIAGNOSTIC RESET" switch

(2) Engine control switch

(3) "EMERGENCY STOP" button

Engine Control Switch

(1) "EMERGENCY STOP" button

(2) Engine control switch

(3) Switch for calibration of the oxygen sensor

(4) Speed potentiometer

(5) "IDLE/RATED" switch

(6) "DIAGNOSTIC RESET" switch

Engine Control Switch

(1) "LOCAL HIGH" indicator

(2) "LOCAL LOW" indicator

(3) Local speed potentiometer

(4) "LOCAL" indicator

(5) "REMOTE/LOCAL" switch

(6) "REMOTE" indicator

(7) "IDLE/RATED" switch

(8) Switch for calibration of the oxygen sensor

(9) "CIRCUIT BREAKER" reset

(10) "DIAGNOSTIC RESET" switch

This panel has a Remote Speed Control (RSC).

During operation, the RSC illuminates these indicators:

Distribution Panel for CSA

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