6ignition System Opera y Ubicacion Comp G3516-4EK

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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
i02033284
Ignition System
SMCS - 1550
The Caterpillar Electronic Ignition System (EIS) was designed to replace the type of ignition system that has
a magneto. The following benefits are the most significant advantages of the EIS:
Diagnostics of the engine control system
Elimination of parts that are prone to mechanical wear
Precise control of ignition timing
Protection from detonation
The EIS includes these components: EIS control module, engine speed/timing sensor, manifold air pressure
sensor, detonation sensors, ignition transformers, spark plugs and wiring harnesses. The EIS control module is
wired to an engine mounted junction box. The junction box provides an interface for communication between
the operator and the EIS control module via the Caterpillar Electronic Technician (Cat ET) or a Digital
Diagnostic Tool (DDT).
Illustration 1 demonstrates the relationship between the parts of the system.
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Illustration 1 g01048857
EIS control module (6) is mounted on the engine. The EIS control module must be programmed for the
installation in order to properly control the ignition. Cat ET (7) or DDT (8) is used to program the EIS control
module. Either electronic service tool can be connected to remote control panel (1) or junction box (2) .
Note: For information on the programmable parameters, refer to Systems Operation, "Electronic Control
System Parameters". For information on the monitoring system, refer to Systems Operation, "Engine
Monitoring System".
Two switches have an effect on the ignition system: the engine control switch and the switch for fuel
selection.
When the engine control switch on remote control panel (1) is switched to the manual start position, the EIS
control module begins operating the ignition system.
If the switch for fuel selection is in the natural gas position, the EIS control module will use the desired
timing that is programmed. If the switch for fuel selection is in the propane position, the EIS control module
retards the timing by six degrees.
The EIS control module uses engine speed/timing sensor (3), manifold air pressure sensor (4), and detonation
sensors (5) to monitor engine operation. The EIS control module determines the optimum ignition timing for
the engine operation and the module initiates the timed ignition via ignition transformers (9) and spark plug
(10) .
Information from the EIS control module is sent to engine mounted junction box (2) and the remote control
panel. If a problem with the electronic system is detected, a diagnostic code is generated. The diagnostic code
can be monitored with the remote control panel or with an electronic service tool.
Note: If the engine has air/fuel ratio control, the EIS control module communicates with the ECM via the
CAT Data Link.
The EIS control module has several internal components that perform different functions. The components
and the functions are listed in Table 1.
Table 1
Internal Components and Functions of the EIS Control Module

Component Function
Receive input from the engine control switch, the switch for
fuel selection, and the DDT.
Provide information on engine status and diagnostics to
Ignition control electronic service tools.
Provide desired timing and voltage to the ignition
transformers' control.
Receive input from the interpreters and the filter.
Receive input from the ignition control.
Provide voltage to the transformers.
Ignition transformers' control
Provide input to the interpreter of diagnostics for the
transformers.
Interpreter of diagnostics for the Receive input from the ignition transformers' control.
transformers Provide input to the ignition control.
Interpreter for the signal from the engine Receive input from the engine speed/timing sensor.
speed/timing sensor Provide input to the ignition control.
Interpreter for the signal from the manifold Receive input from the manifold air pressure sensor.
air pressure sensor Provide input to the ignition control.
Receive input from the detonation sensors.
Filter for the detonation sensors
Provide input to the ignition control.
The relationships of the EIS control module, the sensors, and the transformers are described below.
Distribution Panel
An optional distribution panel (1) may be attached to EIS control module (3). Conduit (2) is used from the
distribution panel to the engine block for the primary circuit for the transformers. The distribution panel is
used for engines that are configured for Canadian Standards Association (CSA) requirements.
Engine Speed/Timing Sensor

The engine speed/timing sensor provides information about engine speed and the position of the crankshaft to
the EIS control module.
(1) Engine speed/timing sensor
A timing wheel is mounted on the rear of the left camshaft. Engine speed/timing sensor (1) is installed in the
cover. A magnetic pickup is located in the plastic sliphead of the sensor. The EIS control module supplies
approximately 13 VDC to the sensor. As the teeth of the timing wheel rotate past the sliphead of the sensor,
the sensor generates a signal that matches the pattern of the teeth. The signal is sent to an interpreter for the
EIS control module.
Engine speed/timing sensor and timing wheel
The timing wheel has a special tooth pattern that indicates the position of the camshaft and the direction of
rotation. The timing wheel has 24 slots in the outer diameter. Twenty-one of the slots are narrow. Three of the
slots are about 2.5 times wider than the rest of the slots. When the engine rotates in the normal direction, the
slots pass the engine speed/timing sensor in the following order:
1 wide slot
3 narrow slots
2 wide slots
18 narrow slots
The number one cylinder is at the top center position when the edge of the third narrow slot passes the center
of the sliphead. All 24 teeth pass the sliphead during one revolution of the camshaft or two revolutions of the
crankshaft.
With information from the engine speed/timing sensor, the EIS control module is able to calculate the
positions of the pistons in the cylinders. According to the ignition timing that is selected, the EIS control
module sends voltage pulses to the transformers for firing of the spark plugs.
The engine speed/timing sensor also monitors engine speed. If a speed sensitive timing map is selected, the
EIS control module adjusts the ignition timing according to the engine rpm.
The EIS control module will shut down the engine if problems with the engine speed/timing sensor's electrical
circuit are detected. The corresponding diagnostic code is generated.
Manifold Air Pressure Sensor
Previous design of the manifold air pressure sensor
New design of the manifold air pressure sensor
The EIS control module supplies approximately 13 VDC to the manifold air pressure sensor. The sensor
monitors the absolute inlet manifold air pressure. The sensor sends a signal to the EIS control module. The
EIS control module has an interpreter that uses the signal to calculate the engine load. If a timing map that is
sensitive to load is selected, the EIS control module adjusts the ignition timing according to the calculated
load.
The EIS control module will generate a diagnostic code if problems with the manifold air pressure sensor's
electrical circuit are detected.
Note: If the engine has the air/fuel ratio control, the ECM sends information from the inlet manifold pressure
sensor to the EIS control module via the CAT Data Link. If the engine does not have the air/fuel ratio control,
the inlet manifold pressure sensor sends information directly to the EIS control module.
Detonation Sensors
Previous design of the detonation sensor
(1) Buffer module
(2) Accelerometer
New design of the detonation sensor
(2) Accelerometer
A previous detonation sensor includes buffer module (1), accelerometer (2), and wiring. A current detonation
sensor includes an integral buffer module, accelerometer (2) and wiring. A detonation sensor is located on the
upper cylinder block on each side of the engine. Each sensor monitors one bank of cylinders. The EIS control
module supplies approximately 13 VDC to the sensors.
The detonation sensors provide an electrical signal of the mechanical engine vibrations to the EIS control
module. The accelerometers provide electrical signals to the buffer modules. The buffers provide a signal
with an offset of approximately 6 VDC to a filter in the EIS control module. The signal indicates mechanical
engine vibrations. The frequency of the signal corresponds to the mechanical frequency of the vibrations. The
amplitude of the signal is proportional to the intensity of the vibrations.
The EIS control module monitors the signals in order to determine the presence and the severity of
detonation. The EIS control module retards the timing in order to limit detonation levels.
The retardation of timing is the first level of protection against detonation. The EIS control module can retard
timing by as few as 0.1 degrees for light detonation levels. The timing can be retarded up to six degrees for
severe detonation.
As the detonation level decreases, the EIS control module will begin to advance the timing out of the
detonation retarded timing. The advance is proportional to the level of detonation. The rate is faster for lighter
detonation. The fastest rate of advance is two degrees per minute.
Engine shutdown is the second level of protection against detonation. If retardation of the timing is
unsuccessful and the detonation continues at severe levels, the EIS control module will signal for an engine
shutdown.
Protection from detonation is enabled under the following conditions:
The inlet manifold air pressure reaches an absolute pressure of 60 kPa (241 inches of H2O).
If a diagnostic code is generated for the manifold air pressure sensor, protection from detonation is
enabled regardless of the inlet manifold air pressure.
Protection from detonation is disabled under the following conditions:
The inlet manifold air pressure reaches an absolute pressure of less than 60 kPa (241 inches of H2O).
The engine speed is less than 500 rpm.
The EIS control module will generate a diagnostic code if a problem with the electrical circuit for the
detonation sensors is detected.
Ignition Transformers
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(1) Ignition transformer
(2) Spark plug
(3) Ignition harness
(4) Bulkhead connector
(5) EIS control module
Each cylinder has an ignition transformer that is located under the valve cover. Each transformer has a
primary circuit and a secondary circuit.
To initiate combustion in a cylinder, the EIS control module sends a pulse of approximately 190 volts to the
primary coil of the ignition transformer. The transformer increases the voltage to a range between 8000 and
32,000 volts. The high voltage creates a spark across the spark plug electrode.
The transformers are grounded through the valve covers. Use caution when a valve cover is removed.
Ignition systems can cause electrical shocks. Avoid contacting the

ignition system components and wiring.
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Do not attempt to remove the valve covers when the engine is operating.
The transformers are grounded to the valve covers. Personal injury or
death may result and the ignition system will be damaged if the valve
covers are removed during engine operation. The engine will not
operate without the valve covers.
Always disconnect the ignition harness from the transformer when a valve cover is removed.
The ignition harness is routed inside the engine to a bulkhead connector on the front housing of the engine.
Another wiring harness connects the transformers to the EIS control module.
The EIS control module monitors the ignition system. The EIS control module will generate a diagnostic code
if problems with the electrical circuit are detected.
Copyright 1993 - 2010 Caterpillar Inc. Mon Jul 12 18:59:44 UTC-0300 2010
All Rights Reserved.
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G3516 Engine Electronic Ignition System 4EK00001-UP(SEBP2185 - 64) - Document ...

Product: GAS ENGINE

Diagnostics of the engine control system

Elimination of parts that are prone to mechanical wear

Precise control of ignition timing

Protection from detonation

Illustration 1 demonstrates the relationship between the parts of the system.

and the functions are listed in Table 1.

Internal Components and Functions of the EIS Control Module

Engine Speed/Timing Sensor

Manifold Air Pressure Sensor

(1) Buffer module

Protection from detonation is enabled under the following conditions:

Protection from detonation is disabled under the following conditions:

The engine speed is less than 500 rpm.

(2) Spark plug

(3) Ignition harness

(4) Bulkhead connector

(5) EIS control module

Ignition systems can cause electrical shocks. Avoid contacting the

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