Motor C9 Sistemas

C-9 ENGINE SYSTEMS AND CONTROLS

© 2001 Caterpillar Inc.

CYLINDER AND VALVE LOCATION INLET VALVES

6

EXHAUST VALVES

5

FIRING ORDER 1 5 3 6 2 4

4

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

3

2

1

AIR INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD

EXHAUST VALVE

INTAKE HEATER

INLET VALVE

AFTER COOLER

AIR INLET

EXHAUST OUTLET TURBOCHARGER

COMPRESSOR TURBINE SIDE SIDE

TURBOCHARGER OIL BEARING TURBINE TURBINE INLET HOUSING WHEEL PORT

COMPRESSOR HOUSING

EXHAUST OUTLET

AIR INLET

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 COOLER OIL FILTER

COOLING SYSTEM EXPANSION TANK WATER TEMPERATURE REGULATOR HOUSING CYLINDER HEAD

BYPASS HOSE

CYLINDER BLOCK

OIL COOLER

WATER PUMP

RADIATOR

CRANKSHAFT OIL FLOW OIL GALLERY

MAIN BEARINGS (7) 7

5

6 6

5

3

4 4

3

ROD BEARINGS (6)

2 2

1 1

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

6 DRIVERS

DISCONNECT SWITCH 3 RETURNS ENGINE RETARDER SOLENOIDS TIMING CALIBRATION CONNECTOR

24 V

20 AMP FUSE 20 AMP BREAKER MAIN POWER RELAY

KEY START SWITCH

CRANK WITHOUT INJECT PLUG

ECM POWER SUPPLY CIRCUIT BATTERY

ENGINE BLOCK GROUND BOLT (-)

24 VOLTS DC (+)

20 A DISCONNECT SWITCH

FUSE

P1 J1

61 63 65 48 52 53 70

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

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

WIRE FUNCTION COLOR CODE (+) BATTERY SUPPLY WIRES INPUT SIGNAL WIRES TO ECM

R

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

ECM CONNECTOR (P1)

1

2

3

4

5

6

8

9

10

11 12 13

13

1

23

14

31

24

39

32

47

40

40

47

57

48

48

57

70

58

14

31

24 36

58 59 60 61 62

ECM SIDE

23

>PEI<

63

65 66 67 68 69 70

HARNESS SIDE

INJECTOR AND COMPRESSION BRAKE SOLENOID CIRCUITS 2 1 BRAKE SOLENOID CYL. 1

J301 P301 1 2

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

INJECTOR SOLENOID CYL. 3 INJECTOR SOLENOID CYL. 4

INJECTOR SOLENOID CYL. 5

INJECTOR SOLENOID CYL. 6

12 1 18 11 2 17 10 3 16 9 4 15 8 5 14 7 6 13 P300 J300

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

20 36 44 21 37 45 28 38 46 29 39 47 65 54 67 66 55 68 P2

J2

ECM

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

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

J204/P204 C B A

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

J203/P203 C B A

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

J209/P209 C B A

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

J201/P201 C B A

ANALOG SENSOR POWER SUPPLY CIRCUIT 5 ± 0.5 VOLTS P2 J2

ECM

40 27

TURBO OUTLET PRESSURE SIGNAL HYDRAULIC OIL PRESSURE SIGNAL

14 3 2

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

18

FUEL PRESSURE SIGNAL

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

4 5

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

DIGITAL SENSOR POWER SUPPLY CIRCUIT

FAN SPEED SENSOR +V DIGITAL DIGITAL RETURN SIGNAL

P1 J1

A B C

8 ± 0.5 VOLTS

AIR INTAKE HEATER CIRCUIT AIR INTAKE HEATER LAMP

24V B A

J648 P648

AIR INTAKE HEATER

AIR INTAKE HEATER RELAY

J501 P501 1 2

ECM 850-BU

1

AIR INTAKE HEATER RELAY

TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT CATERPILLAR MONITORING SYSTEM

TRANSMISSION ECM

CAT DATA LINK + CAT DATA LINK -

J63

A B C D E F G SERVICE TOOL CONNECTOR

8 7

8 7

CAT DATA LINK + CAT DATA LINK -

ENGINE ECM

P1 J1 70 65

BAT + (SWITCHED) BAT -

8 9 34 50

CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +

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

DEGREES BTDC

FUEL RPM SELECT TIMING

DESIRED TIMING BTDC

CONVERT DESIRED TIMING

FUEL INJECTION TIMING WAVE FORM

C-9 ELECTRONIC GOVERNOR

HYDRAULIC OIL TEMPERATURE AND PRESSURE SENSORS

SHUTDOWNS

ECM TO PUMP CONTROL VALVE

ELECTRONIC GOVERNOR

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

FUEL INJECTION CONTROL

ENGINE RPM

TORQUE MAPS

ENGINE CONTROL LOGIC

THROTTLE

TDC ENGINE RPM

ENGINE RPM SPEED/TIMING SENSORS

TIMING WHEEL

AFRC MAPS

TURBO OUTLET AND ATMOSPHERIC PRESSURE SENSORS

C-9 SPEED/TIMING SENSORS UPPER (HIGH SPEED) SPEED/TIMING SENSOR

J401/P401 1 2

LOWER (CRANKING) SPEED/TIMING SENSOR

J2/P1

ECM

49 48

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

1 2

59 58

- LOWER S/T/ SENSOR + LOWER S/T SENSOR

1 2

22 23

+ TIMING CAL PROBE - TIMING CAL PROBE

J402/P402

SPEED/TIMING SENSING

GEAR TRAIN SHOWN FROM FRONT OF ENGINE

DUAL PASSIVE SENSORS

45° CRANK

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

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

SENSOR A MEASURED TDC NO.1

CAMSHAFT IDLER GEAR

45° CRANK

SENSOR B MEASURED TDC NO.1

LOWER SENSOR LOW SPEED

UPPER SENSOR HIGH SPEED 30° CRANK

15° 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

-90°

-60°

-30°

0°

30°

45°

LOWER SENSOR B TIMING -70°

-45°

-15° -0°

15°

45°

75°

90° 105°

60°

90°

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

ENGINE BLOCK (SHOWN FROM REAR) AIR GAP 1 mm (.040 in)

C-9 TIMING CALIBRATION TIMING WHEEL

REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE

ASSUMED CYL. NO. 1 TDC

-3° TIMING CALIBRATION SENSOR SIGNAL

25 ENGINE DEGREES

ACTUAL CYL. NO. 1 TDC

+3° TIMING REFERENCE OFFSET (MAXIMUM RANGE ± 3 DEGREES)

C-9 SPEED/TIMING SENSORS CALIBRATION UPPER (HIGH SPEED) SPEED/TIMING SENSOR

J401/P401 1 2

LOWER (CRANKING) SPEED/TIMING SENSOR

J2/P1

ECM

49 48

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

59 58

- LOWER S/T/ SENSOR + LOWER S/T SENSOR

22 23

+ TIMING CAL PROBE - TIMING CAL PROBE

J402/P402 1 2

TIMING CALIBRATION PROBE

J400/P400 1 2

TIMING CALIBRATION CONNECTOR

ELECTRONIC SENSORS AND SYSTEMS

ECM 6 INJECTOR SOLENOIDS

6 COMPRESSION BRAKE SOLENOIDS

J2

J1

ECM 6 INJECTOR SOLENOIDS

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

J2

J1

ECM 6 INJECTOR SOLENOIDS

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

J2

J1

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

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR

J2

J1

ECM 6 INJECTOR SOLENOIDS

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

COOLANT TEMP. SENSOR

AIR INTAKE TEMP. SENSOR

J2

J1

ECM 6 INJECTOR SOLENOIDS

6 COMPRESSION BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING SENSORS

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

J2

J1

ENGINE POWER DERATING MAP 100%

7,500

98%

8,210

96%

8,920

94%

9,630

92%

10,340

90%

11,050

88%

11,760

86%

12,470

84%

13,180

82%

13,890

80%

14,600

78%

15,310

76%

16,020

74%

16,730

72%

17,440 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

ATMOSPHERIC PRESSURE IN kPa

ALTITUDE IN FEET

PERCENT OF FULL LOAD POWER

ACCORDING TO ATMOSPHERIC PRESSURE

ECM 6 INJECTOR SOLENOIDS

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)

J2

J1

ECM 6 INJECTOR SOLENOIDS

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

J2

J1

OIL PRESSURE MAP OIL PRESSURE WARNING AND DERATE TRIP POINTS 190

27.6

180

26.1

175 kPa (25 psi) RESET LINE

170

24.7

160

23.2

150

154 kPa (22 psi) TRIP LINE

21.8 20.3

130

18.9

125 kPa (18 psi) RESET LINE

120

17.4

110

16.0

100

14.5

104 kPa (15 psi) TRIP LINE

90

13.1

80

11.6

70

10.2

60

8.7

LOW OIL PRESSURE WARNING

7.3

50

VERY LOW OIL PRESSURE DERATE

40

5.8

30

4.4

20

2.9

10

1.5

0

0

400

500

600

kPa x 0.145 = PSI

700

800

900

1000

1100

1200

1300

ENGINE RPM

1400

1500

1600

1700

1800

1900

2000

2200

OIL PRESSURE IN PSI

OIL PRESSURE IN kPa

140

ECM 6 INJECTOR SOLENOIDS

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

J2

J1

ECM 6 INJECTOR SOLENOIDS

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

J2

J1

ECM 6 INJECTOR SOLENOIDS

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

J2

J1

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 B A

J648 P648

AIR INTAKE HEATER

AIR INTAKE HEATER RELAY

J501 P501 1 2

ECM 850-BU

1

AIR INTAKE HEATER RELAY

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

160-0141 SERIAL CABLE (25 FT.) PC SERIAL PORT (COMM PORT)

J1

ENGINE ELECTRONIC CONTROL MODULE (ECM)

SERVICE TOOL CONNECTOR

COMMUNICATION ADAPTER II 171-4400 (GP)

CAT ELECTRONIC TECHNICIAN

LAPTOP COMPUTER

P

15

TRANSMISSION ELECTRONIC CONTROL MODULE

10 5

25 X100

R 24 V

AUT

20

0

MPH km/h

30

CATERPILLAR MONITORING SYSTEM DISPLAY UNIT

44

TYPICAL CAT / CAN DATA LINK CIRCUIT CATERPILLAR MONITORING SYSTEM

TRANSMISSION ECM

CAT DATA LINK + CAT DATA LINK -

J63

A B C D E F G SERVICE TOOL CONNECTOR

8 7

8 7

P1 J1 70 65 42 8 9 34 50

CAT DATA LINK + CAT DATA LINK -

ENGINE ECM

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