C-9 ENGINE SYSTEMS AND CONTROLS

2001 Caterpillar Inc.

CYLINDER AND VALVE LOCATION

INLET VALVES FIRING ORDER 1 5 3 6 2 4

EXHAUST VALVES

BORE 112 MM (4.4 IN) STROKE 149 MM (5.9 IN)

AIR INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD

INTAKE HEATER

AFTER COOLER

EXHAUST VALVE

INLET VALVE

AIR INLET

EXHAUST OUTLET TURBOCHARGER

COMPRESSOR TURBINE SIDE SIDE

TURBOCHARGER
COMPRESSOR HOUSING OIL BEARING TURBINE TURBINE INLET HOUSING WHEEL PORT

AIR INLET

EXHAUST OUTLET

COMPRESSOR WHEEL

BEARING

OIL OUTLET PORT

EXHAUST INLET

VALVE SYSTEM COMPONENTS

ROCKER ARM PUSH ROD BRIDGE

SPRING

VALVE

LIFTER

C-9 LUBRICATION SYSTEM

HEUI PUMP

TO TURBOCHARGER OIL FILTER

OIL COOLER

COOLING SYSTEM
EXPANSION TANK WATER TEMPERATURE REGULATOR HOUSING CYLINDER HEAD

CYLINDER BLOCK

BYPASS HOSE

OIL COOLER

WATER PUMP

RADIATOR

CRANKSHAFT OIL FLOW

OIL GALLERY

MAIN BEARINGS (7) 7 6 6 5 5 4 4 3 3 2 2 1 1

ROD BEARINGS (6)

RUBBER VIBRATION DAMPER

CRANKSHAFT RING RUBBER RING HUB

ALIGNMENT

VISCOUS VIBRATION DAMPER

CRANKSHAFT

WEIGHT

CASE

C-9 HEUI SYSTEM POWER SUPPLIES

ECM Injectors and Compression Brake Pump Control Valve Analog Sensors Digital Sensors Air Intake Heater Service Tool

J2

J1

ECM GROUND BOLT DISCONNECT SWITCH 24 V

6 DRIVERS

3 RETURNS ENGINE RETARDER SOLENOIDS TIMING CALIBRATION CONNECTOR 20 AMP FUSE 20 AMP BREAKER MAIN POWER RELAY

KEY START SWITCH

CRANK WITHOUT INJECT PLUG

ECM POWER SUPPLY CIRCUIT

BATTERY (-) 24 VOLTS DC (+) DISCONNECT SWITCH WIRE FUNCTION COLOR CODE (+) BATTERY SUPPLY WIRES INPUT SIGNAL WIRES TO ECM OUTPUT SIGNAL WIRES FROM ECM SENSOR SUPPLY VOLTAGE SIGNAL PLUS SIGNAL MINUS (-) BATTERY / SENSOR RETURN 15 AMP CIRCUIT BREAKER C OFF S ON B ST KEY SWITCH R ENGINE BLOCK GROUND BOLT

P1 J1

20 A
FUSE

61 63 65 48 52 53 70

(-) (-) (-) (+) (+) (+) (+)

ECM (C-9) BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY SWITCHED POWER

ECM CONNECTOR (P1)

13 23 31 39 47 57 70

1 14 24 32 40 48 58 40 48 14 24

10

11 12 13 23 31

>PEI<

36 47 57

58 59 60 61 62

63

65 66 67 68 69 70

ECM SIDE

HARNESS SIDE

INJECTOR AND COMPRESSION BRAKE SOLENOID CIRCUITS

2 1 BRAKE SOLENOID CYL. 1 2 1 BRAKE SOLENOID CYL. 2 J302 P302 1 2 2 1 BRAKE SOLENOID CYL. 3 J303 P303 1 2 2 1 BRAKE SOLENOID CYL. 4 J304 P304 1 2 INJECTOR SOLENOID CYL. 1 2 1 BRAKE SOLENOID CYL. 5 J305 P305 1 2 INJECTOR SOLENOID CYL. 2 2 1 BRAKE SOLENOID CYL. 6 J306 P306 1 2 12 1 18 11 2 17 10 3 16 9 4 15 8 5 14 7 6 13 P300 J300 P2 20 36 44 21 37 45 28 38 46 29 39 47 65 54 67 66 55 68 J2 BRAKE RETURN CYL 1 INJECTOR/BRAKE CYL 1 INJECTOR RETURN CYL 1 BRAKE RETURN CYL 2 INJECTOR/BRAKE CYL 2 INJECTOR RETURN CYL 2 BRAKE RETURN CYL 3 INJECTOR/BRAKE CYL 3 INJECTOR RETURN CYL 3 BRAKE RETURN CYL 4 INJECTOR/BRAKE CYL 4 INJECTOR RETURN CYL 4 BRAKE RETURN CYL 5 INJECTOR/BRAKE CYL 5 INJECTOR RETURN CYL 5 BRAKE RETURN CYL 6 INJECTOR/BRAKE CYL 6 INJECTOR RETURN CYL 6 ECM

J301 P301 1 2

INJECTOR SOLENOID CYL. 3 INJECTOR SOLENOID CYL. 4

INJECTOR SOLENOID CYL. 5

INJECTOR SOLENOID CYL. 6

PUMP CONTROL VALVE POWER SUPPLY

PUMP CONTROL VALVE SUPPLY RETURN

J500 P500 A B

P2 J2 61 62

ECM (C-9 HEUI) + CONTROL VALVE - CONTROL VALVE

TURBO OUTLET PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3

J200/P200 C B A J204/P204 C B A J203/P203 C B A J209/P209 C B A

ANALOG SENSOR POWER SUPPLY CIRCUIT

5 0.5 VOLTS
P2 J2 40 27 ECM TURBO OUTLET PRESSURE SIGNAL HYDRAULIC OIL PRESSURE SIGNAL

HYDRAULIC OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1

ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1

14 3 2

ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1

FUEL PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1

18

FUEL PRESSURE SIGNAL

ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3

J201/P201 C B A

24 42 41

ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3

THROTTLE POSITION SENSOR

+V DIGITAL DIGITAL RETURN SIGNAL

J405 P405 A B C

P1 J1 4 5

ECM (C-9 HEUI) + V DIGITAL SUPPLY - V DIGITAL RETURN

FAN SPEED SENSOR

+V DIGITAL DIGITAL RETURN SIGNAL A B C

DIGITAL SENSOR POWER SUPPLY CIRCUIT

8 0.5 VOLTS

AIR INTAKE HEATER CIRCUIT

AIR INTAKE HEATER LAMP

24V J648 P648 AIR INTAKE HEATER AIR INTAKE HEATER RELAY B A J501 P501 1 2 850-BU 1

ECM AIR INTAKE HEATER RELAY

TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT

TRANSMISSION ECM CATERPILLAR MONITORING SYSTEM

CAT DATA LINK + CAT DATA LINK -

8 7

8 7

CAT DATA LINK + CAT DATA LINK -

J63

A B C D E F G
SERVICE TOOL CONNECTOR

P1 J1 70 65

ENGINE ECM

BAT + (SWITCHED) BAT CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +

8 9 34 50

ELECTRONIC CONTROL SYSTEM

HEUI INJECTOR TESTING METHODS

Injector Solenoid Test Manual Cylinder Cutout Automatic Cylinder Cutout Test

C-9 HEUI CONTROL LOGIC

TIMING CONTROL
ENGINE SPEED FUEL QUANTITY HYDRAULIC OIL TEMPERATURE TIMING FUEL RPM SELECT TIMING DEGREES BTDC DESIRED TIMING BTDC FUEL INJECTION TIMING WAVE FORM

CONVERT DESIRED TIMING

C-9 ELECTRONIC GOVERNOR

SHUTDOWNS

HYDRAULIC OIL TEMPERATURE AND PRESSURE SENSORS ECM

TO PUMP CONTROL VALVE 6 5 SIGNALS TO FUEL 4 INJECTORS 3 2 1 SPEED/TIMING SIGNAL

ELECTRONIC GOVERNOR TORQUE MAPS

FUEL INJECTION CONTROL

ENGINE RPM TDC

AFRC MAPS

ENGINE CONTROL LOGIC

THROTTLE

ENGINE RPM SPEED/TIMING SENSORS TURBO OUTLET AND ATMOSPHERIC PRESSURE SENSORS

ENGINE RPM

TIMING WHEEL

C-9 SPEED/TIMING SENSORS

UPPER (HIGH SPEED) SPEED/TIMING SENSOR

J401/P401 1 2 J2/P1 49 48

ECM
- UPPER S/T SENSOR + UPPER S/T SENSOR

LOWER (CRANKING) SPEED/TIMING SENSOR

J402/P402 1 2 59 58 - LOWER S/T/ SENSOR + LOWER S/T SENSOR

1 2

22 23

+ TIMING CAL PROBE - TIMING CAL PROBE

GEAR TRAIN SHOWN FROM FRONT OF ENGINE

SPEED/TIMING SENSING
45 CRANK

DUAL PASSIVE SENSORS

UPPER SPEED/TIMING SENSOR A (75 TO 230 OHMS)

LOWER SPEED/TIMING SENSOR B (600 TO 1800 OHMS)

CAMSHAFT IDLER GEAR

SENSOR A MEASURED TDC NO.1 SENSOR B MEASURED TDC NO.1 LOWER SENSOR LOW SPEED 15 CRANK

45 CRANK UPPER SENSOR HIGH SPEED 30 CRANK

CRANKSHAFT GEAR

GEAR ROTATION SENSOR B TDC NO.1 SENSOR A TDC NO.1 SENSOR B TDC NO.5 SENSOR A TDC NO.5

SENSOR SIGNALS

UPPER SENSOR A TIMING LOWER SENSOR B TIMING -70

-90 -45

-60 -15 -0

-30 15

0 45

30 75

45

60

90

90 105

C-9 TIMING CALIBRATION PROBE INSTALLATION

TDC POSITION CRANKSHAFT COUNTERWEIGHT

MACHINED FACE

DIRECTION OF ROTATION TIMING CALIBRATION PROBE POSITIONED 85 CRANKSHAFT DEG. AFTER TDC TIMING CALIBRATION SLOT AIR GAP 1 mm (.040 in)

ENGINE BLOCK (SHOWN FROM REAR)

C-9 TIMING CALIBRATION

TIMING WHEEL

REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE ASSUMED CYL. NO. 1 TDC

ACTUAL CYL. NO. 1 TDC

-3 TIMING CALIBRATION SENSOR SIGNAL

+3 TIMING REFERENCE OFFSET (MAXIMUM RANGE 3 DEGREES)

25 ENGINE DEGREES

C-9 SPEED/TIMING SENSORS CALIBRATION

UPPER (HIGH SPEED) SPEED/TIMING SENSOR

J401/P401 1 2 J2/P1 49 48

ECM
- UPPER S/T SENSOR + UPPER S/T SENSOR

LOWER (CRANKING) SPEED/TIMING SENSOR

J402/P402 1 2 59 58 - LOWER S/T/ SENSOR + LOWER S/T SENSOR

TIMING CALIBRATION PROBE

J400/P400 1 2 22 23 + TIMING CAL PROBE - TIMING CAL PROBE

TIMING CALIBRATION CONNECTOR

ELECTRONIC SENSORS AND SYSTEMS

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

ANALOG SENSORS
Coolant temperature Air intake temperature Hydraulic oil temperature Hydraulic oil pressure Atmospheric pressure Turbocharger outlet pressure Lubrication oil pressure

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR

AIR INTAKE TEMP. SENSOR

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR

ENGINE POWER DERATING MAP

ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500 8,210 8,920 9,630

PERCENT OF FULL LOAD POWER

98% 96% 94% 92% 90% 88% 86% 84% 82% 80% 78% 76% 74% 72% 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53

11,050 11,760 12,470 13,180 13,890 14,600 15,310 16,020 16,730 17,440

ATMOSPHERIC PRESSURE IN kPa

ALTITUDE IN FEET

10,340

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR (BOOST)

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR

OIL PRESSURE MAP

OIL PRESSURE WARNING AND DERATE TRIP POINTS
190 180 170 160 150 140 154 kPa (22 psi) TRIP LINE 175 kPa (25 psi) RESET LINE 27.6 26.1 24.7 23.2 21.8 20.3

OIL PRESSURE IN kPa

120 110 100 90 80 70 60 50 40 30 20 10 0 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 LOW OIL PRESSURE WARNING VERY LOW OIL PRESSURE DERATE 104 kPa (15 psi) TRIP LINE

17.4 16.0 14.5 13.1 11.6 10.2 8.7 7.3 5.8 4.4 2.9 1.5 0 2200

kPa x 0.145 = PSI

ENGINE RPM

OIL PRESSURE IN PSI

130

125 kPa (18 psi) RESET LINE

18.9

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR FUEL PRESSURE SENSOR

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

OIL VISCOSITY SELECTION CONNECTOR

ECM 6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

HYDRAULIC OIL PRESS. SENSORS

DIGITAL SENSORS AND CIRCUITS Throttle Position Sensor Fan Speed Sensor

J2

J1

ECM

GROUND BOLT

DISCONNECT SWITCH

24 V 20 AMP FUSE 20 AMP BREAKER MAIN POWER RELAY

KEY SWITCH

PULSE WIDTH MODULATED SIGNALS

10% ON DUTY = 10% CYCLE OFF 50% ON DUTY = 50% CYCLE OFF 1 CYCLE 90% ON DUTY = 90% CYCLE OFF DUTY CYCLE = PERCENT OF TIME ON VS PERCENT OF TIME OFF

GROUND LEVEL SHUTDOWN SWITCH CIRCUIT

GROUND LEVEL SHUTDOWN SWITCH 1 2 3

P1 J1 2 8 29

ECM GND. LEVEL SHUTDOWN (NO) GND. LEVEL SHUTDOWN (NC) DIGITAL RETURN

USER DEFINED SHUTDOWN CIRCUIT

P1 J1 USER SHUTDOWN DEVICE 59 5

ECM USER DEFINED SHUTDOWN DIGITAL RETURN

AIR INTAKE HEATER CIRCUIT

AIR INTAKE HEATER LAMP

24V J648 P648 AIR INTAKE HEATER AIR INTAKE HEATER RELAY B A J501 P501 1 2 850-BU 1

ECM AIR INTAKE HEATER RELAY

CAT DATA LINK

160-0133 UNIVERSAL DATA LINK CABLE (2 FT.)
J2 J1

ENGINE ELECTRONIC CONTROL MODULE (ECM)

SERVICE TOOL CONNECTOR

160-0141 SERIAL CABLE (25 FT.) PC SERIAL PORT (COMM PORT) COMMUNICATION ADAPTER II 171-4400 (GP) LAPTOP COMPUTER
CAT ELECTRONIC TECHNICIAN

15

P
AUT

TRANSMISSION ELECTRONIC CONTROL MODULE

10 5

20 25 X100

R
24 V 0 MPH km/h

30

44

CATERPILLAR MONITORING SYSTEM DISPLAY UNIT

TYPICAL CAT / CAN DATA LINK CIRCUIT

TRANSMISSION ECM CATERPILLAR MONITORING SYSTEM

CAT DATA LINK + CAT DATA LINK -

8 7

8 7

CAT DATA LINK + CAT DATA LINK -

J63

A B C D E F G
SERVICE TOOL CONNECTOR

P1 J1 70 65 42 8 9 34 50

ENGINE ECM

BAT + (SWITCHED) BAT SHIELD CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +