PLUG 7C6204 - Caterpillar

The engine is designed for electronic control of most engine operating functions. The electronic system consists of the following components: Electronic Control Module (ECM), wiring harness, switches, sensors and electronic fuel injectors.Electronic Controls
Electronic Control Module
The ECM controls the engine operation. The ECM consists of two main components, the control computer (hardware) and the personality module (software). The control computer consists of a microprocessor and electronic circuitry. The personality module is the software for the control computer which contains operating maps that define power and torque curves. The ECM monitors the engine parameters during operation. The ECM supplies signals to the electronic fuel injectors. The ECM governs engine speed. Desired engine speed is determined by the throttle position sensor signal and certain sensor readings. Diagnostic codes may derate the engine. Actual engine speed is supplied to the ECM by the engine speed/timing sensor.Fuel Injection
The ECM controls the timing of the engine by varying the signals to the electronic solenoids that control fuel injection. Fuel is injected only while an injector solenoid is energized by a 105 volt signal from the ECM. By controlling the timing and duration of the 105 volt signal, the ECM controls the fuel injection timing, the quantity of fuel and the desired engine speed. Injection timing depends on desired engine speed, load, and other operational factors.The ECM limits engine power during cold mode operation. The ECM may modify the injection timing and the ECM may cut out certain engine cylinders. This will increase startability and this will reduce warm up time. Cold mode is activated whenever the engine coolant temperature falls below a predetermined value. Cold mode remains active until the engine has warmed or a time limit is exceeded. The ECM is programmed at the factory which limits the quantity of fuel that can be injected. The position of the Fuel Ratio Control (FRC) controls the fuel limit for exhaust smoke. The FRC is based on the maximum allowable ratio of fuel to air. The FRC fuel position is increased when the ECM senses a higher turbocharger compressor outlet pressure. This will allow more fuel into the cylinder.The rated fuel position is a limit that is based on the engine power rating. This is similar to the rack stops and the torque spring on a mechanically governed engine. The rated fuel position limits the power curve and the torque curve for a specific engine family.Engine Wiring Diagram
Illustration 1 g00995630
Typical example
Location of the Engine Components
Illustration 2 g01019029
Left side view
(1) Unfiltered fuel pressure sensor
(2) Filtered fuel pressure sensor
(3) Aftercooler temperature sensor
(4) Coolant temperature sensor
(5) Secondary ECM connector J2
(6) Left exhaust temperature sensor
(7) Left turbocharger compressor inlet pressure sensor
(8) Secondary engine speed/timing sensor
(9) Primary engine speed/timing sensor
(10) Secondary ECM connector J1
(11) Secondary ECM Location of the Engine Components
Illustration 3 g01019032
Right side view
(12) Right turbocharger compressor inlet pressure sensor
(13) Right exhaust temperature sensor
(14) Crankcase pressure sensor Location of the Engine Components
Illustration 4 g01019034
Front and rear view
(4) Coolant temperature sensor
(15) Filtered engine oil pressure sensor
(16) Unfiltered engine oil pressure sensor
(3) Aftercooler temperature sensor
(17)