Motor C9 Sistemas

CCCC----9999 EEEENNNNGGGGIIIINNNNEEEESSSSYYYYSSSSTTTTEEEEMMMMSSSS AAAANNNNDDDD CCCCOOOONNNNTTTTRRRROOOOLLLLSSSS

© 2001 Caterpillar Inc.

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EXHAUSTVALVES

INLETVALVES

CYLINDER AND VALVE LOCATION

FIRING ORDER 1 5 3 6 2 4

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

AIRINLET

EXHAUSTOUTLET

EXHAUSTMANIFOLD

EXHAUSTVALVE

INLETVALVE

COMPRESSORSIDE

TURBINESIDE

TURBOCHARGER

INTAKEHEATER AFTER COOLER

AIR INTAKE AND EXHAUST SYSTEM

AIRINLET

COMPRESSORHOUSING

COMPRESSORWHEEL BEARING

OILOUTLET PORT

TURBINEHOUSING

BEARING TURBINEWHEEL

EXHAUSTOUTLET

EXHAUST INLET

OILINLET PORT

TURBOCHARGER

PUSH ROD

LIFTER

ROCKER ARM

BRIDGE

VALVE

SPRING

VALVE SYSTEM COMPONENTS

OIL FILTER

OIL COOLER

HEUI PUMP

TOTURBOCHARGER

C-9 LUBRICATION SYSTEM

CYLINDERHEAD

CYLINDERBLOCK

OILCOOLER

WATERPUMP RADIATOR

BYPASSHOSE

EXPANSION TANKWATER TEMPERATUREREGULATOR HOUSING

COOLING SYSTEM

OIL GALLERY

MAINBEARINGS

(7)

ROD BEARINGS (6)

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CRANKSHAFT OIL FLOW

CRANKSHAFT RING

RUBBER RING

HUB

ALIGNMENT

RUBBER VIBRATION DAMPER

CRANKSHAFT

WEIGHT

CASE

VISCOUS VIBRATION DAMPER

C-9 HEUISYSTEM POWER SUPPLIES

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

J2 J1

6 DRIVERS

3 RETURNS

ENGINE RETARDERSOLENOIDS

ECM

TIMING CALIBRATION CONNECTOR

GROUNDBOLT

20 AMPBREAKER

MAINPOWERRELAY KEY START

SWITCH

24 V

20 AMP FUSE

CRANK WITHOUT INJECT PLUG

DISCONNECT SWITCH

48525370

ECM (C-9)

24 VOLTS DC

(+)

(-)

ENGINE BLOCKGROUND BOLT

15 AMPCIRCUIT BREAKER

BATTERY

R

CSB ST

OFFON

KEY SWITCH

P1 J1

(-) BATTERY(-) BATTERY(-) BATTERY

616365

(+) BATTERY(+) BATTERY(+) BATTERY(+) SWITCHED POWER

(+) BATTERY SUPPLY WIRES

INPUT SIGNAL WIRES TO ECM

OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

SIGNAL PLUS

SIGNAL MINUS

(-) BATTERY / SENSOR RETURN

WIRE FUNCTION COLOR CODE

FUSE

20 A

DISCONNECTSWITCH

ECM POWER SUPPLY CIRCUIT

13

23

31

39

47

57

70

1

14

24

32

40

48

58

1

14

2 3 4 5 6 8 9 10 11 12 13

58 59 60 61 62 63 65 66 67 68 69 70

24

40

48

23

31

47

57

36

>PEI<

ECM SIDE HARNESS SIDE

ECM CONNECTOR (P1)

21

ECM

203644213745283846293947655467665568

BRAKE RETURN CYL 1INJECTOR/BRAKE CYL 1INJECTOR RETURN CYL 1BRAKE RETURN CYL 2INJECTOR/BRAKE CYL 2INJECTOR RETURN CYL 2BRAKE RETURN CYL 3INJECTOR/BRAKE CYL 3INJECTOR RETURN CYL 3BRAKE RETURN CYL 4INJECTOR/BRAKE CYL 4INJECTOR RETURN CYL 4BRAKE RETURN CYL 5INJECTOR/BRAKE CYL 5INJECTOR RETURN CYL 5BRAKE RETURN CYL 6INJECTOR/BRAKE CYL 6INJECTOR RETURN CYL 6

BRAKESOLENOID

CYL. 6

121

18112

17103

1694

1585

1476

13

12

21

1 2

2 1

1 2

1 2

2 1

1 2

2 1

1 2

P300 J300 P2 J2

2 1

INJECTORSOLENOID

CYL. 6

J306 P306

BRAKESOLENOID

CYL. 5

INJECTORSOLENOID

CYL. 5

J305 P305

BRAKESOLENOID

CYL. 4

INJECTORSOLENOID

CYL. 4

J304 P304

BRAKESOLENOID

CYL. 3

INJECTORSOLENOID

CYL. 3

J303 P303

BRAKESOLENOID

CYL. 2

INJECTORSOLENOID

CYL. 2

J302 P302

BRAKESOLENOID

CYL. 1

INJECTORSOLENOID

CYL. 1

J301 P301

INJECTOR AND COMPRESSION BRAKESOLENOID CIRCUITS

+ CONTROL VALVE- CONTROL VALVE

6162

P2 J2

AB

J500 P500PUMP CONTROL

VALVE

SUPPLY RETURN

ECM (C-9 HEUI)

PUMP CONTROL VALVEPOWER SUPPLY

CBA

ENGINE OIL PRESSURE SIGNALANALOG SENSOR RETURN 3

ANALOG SENSOR POWER (+5V) 3

J201/P201244241

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

CBA

FUEL PRESSURE SIGNALANALOG SENSOR RETURN 1


J209/P20918 FUEL PRESSURE SIGNAL

CBA

ATMOSPHERIC PRESSURE SIGNALANALOG SENSOR RETURN 1


J203/P2031432

CBA

HYDRAULIC OIL PRESSURE SIGNALANALOG SENSOR RETURN 1


J204/P2044027

TURBO OUTLET PRESSURE SIGNALHYDRAULIC OIL PRESSURE SIGNAL

CBA

TURBO OUTLET PRESSURE SIGNALANALOG SENSOR RETURN 3


J200/P200

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

ECMP2 J2

ANALOG SENSORPOWER SUPPLY CIRCUIT

5 ± 0.5 VOLTS

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

45

DIGITAL SENSORPOWER SUPPLY CIRCUIT

P1 J1

ABC

J405 P405

ABC

+V DIGITALDIGITAL RETURN

SIGNAL

FAN SPEED SENSOR

THROTTLEPOSITION SENSOR

+V DIGITALDIGITAL RETURN

SIGNAL

8 ± 0.5 VOLTS

24V

12

BAAIR INTAKE

HEATER RELAY

AIR INTAKEHEATER LAMP

J501 P501

J648

P648

850-BU 1 AIR INTAKEHEATER RELAY

ECM

AIR INTAKE HEATER CIRCUIT

AIR INTAKEHEATER

ABCDEFG

7065

8 93450

BAT + (SWITCHED)BAT -

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

SERVICE TOOLCONNECTOR

J63 P1 J1 ENGINE ECM

87

CAT DATA LINK +CAT DATA LINK -

87


TRANSMISSION ECMCATERPILLAR

MONITORING SYSTEM

TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT

ELECTRONIC CONTROLSYSTEM

HEUI INJECTOR TESTINGMETHODS

• Injector Solenoid Test

• Manual Cylinder Cutout

• Automatic Cylinder Cutout Test

ENGINE SPEED

FUEL QUANTITY FUEL RPMSELECTTIMING

CONVERTDESIREDTIMING

HYDRAULIC OILTEMPERATURE

TIMING CONTROL

DEGREES BTDC DESIREDTIMINGBTDC

TIMINGFUEL INJECTION

TIMING WAVE FORM

C-9 HEUI CONTROL LOGIC

TORQUEMAPS

AFRCMAPS

TURBO OUTLET ANDATMOSPHERIC

PRESSURE SENSORS

ENGINECONTROL

LOGIC

THROTTLE

SHUTDOWNS

ENGINE RPM

TDC

654321

SIGNALSTO FUEL

INJECTORS

FUELINJECTIONCONTROL

SPEED/TIMINGSIGNAL

ENGINE RPM

SPEED/TIMINGSENSORS

TIMINGWHEEL

ENGINE RPM

ECM

HYDRAULIC OILTEMPERATURE AND

PRESSURE SENSORS

C-9ELECTRONIC GOVERNOR

ELECTRONICGOVERNOR

TO PUMPCONTROL

VALVE

5958

12

J402/P402

LOWER (CRANKING)SPEED/TIMING

SENSOR

J2/P112

UPPER (HIGH SPEED)SPEED/TIMING

SENSOR J401/P401

4948

12

2223

ECM

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

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

+ TIMING CAL PROBE- TIMING CAL PROBE

C-9 SPEED/TIMING SENSORS

CAMSHAFTIDLERGEAR

CRANKSHAFTGEAR

LOWERSPEED/TIMING SENSOR B

(600 TO 1800 OHMS)

SENSOR AMEASURED TDC NO.1

SENSOR BMEASURED TDC NO.1

UPPERSPEED/TIMING SENSOR A

(75 TO 230 OHMS)

GEARROTATION

SENSORSIGNALS

UPPER SENSOR A TIMING

LOWER SENSOR B TIMING -70° -45° -15° -0° 15° 75°45° 90° 105°

90°60°45°30°0°-30°-60°-90°

SENSOR BTDC NO.1

SENSOR ATDC NO.1

SENSOR BTDC NO.5

SENSOR ATDC NO.5

15° CRANK 30° CRANK

45° CRANK

SPEED/TIMING SENSINGDUAL PASSIVE SENSORS45° CRANK

UPPER SENSORHIGH SPEED

LOWER SENSORLOW SPEED

GEAR TRAIN SHOWNFROM FRONT OF ENGINE

TIMING CALIBRATION PROBEPOSITIONED 85 CRANKSHAFT

DEG. AFTER TDC

AIR GAP1 mm (.040 in)

TIMING CALIBRATIONSLOT

ENGINE BLOCK(SHOWN FROM REAR)

DIRECTION OFROTATION

MACHINED FACE

CRANKSHAFTCOUNTERWEIGHT

C-9 TIMING CALIBRATIONPROBE INSTALLATION

TDC POSITION

REFERENCE EDGE TO TDC DISTANCE

REFERENCEEDGE ASSUMED

CYL. NO. 1 TDCACTUAL

CYL. NO. 1 TDC

TIMING REFERENCEOFFSET

(MAXIMUM RANGE± 3 DEGREES)

TIMING CALIBRATIONSENSOR SIGNAL

TIMINGWHEEL

C-9 TIMING CALIBRATION

-3° +3°

25 ENGINE DEGREES

TIMING CALIBRATIONPROBE

TIMING CALIBRATIONCONNECTOR

5958

12

J402/P402

LOWER (CRANKING)SPEED/TIMING

SENSOR

J2/P112

UPPER (HIGH SPEED)SPEED/TIMING

SENSOR J401/P401

4948

12

2223

ECM

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

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

+ TIMING CAL PROBE- TIMING CAL PROBE

J400/P400

C-9 SPEED/TIMING SENSORS CALIBRATION

ELECTRONIC SENSORSAND

SYSTEMS

J2 J1

6 COMPRESSIONBRAKE SOLENOIDS

ECM

6 INJECTOR SOLENOIDS

J2 J1


ECM



ENGINE SPEED/TIMINGSENSORS



J2 J1


ECM

Lubricat ion oi l pressure

Turbocharger out let pressure

Atmospheric pressure

Coolant temperature

Hydraul ic oi l temperature

Air intake temperature

Hydraul ic oi l pressure

ANALOG SENSORS

COOLANT TEMP. SENSOR




J2 J1


ECM





J2 J1


ECM

AIR INTAKE TEMP. SENSOR





J2 J1


ECM


ATMOSPHERIC PRESSURE SENSOR

100%

98%

96%

94%

92%

90%

88%

86%

84%

82%

80%

78%

76%

74%

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

8,210

8,920

9,630

10,340

11,050

11,760

12,470

13,890

14,600

15,310

16,020

16,730

17,440

13,180

7,500

72%

ENGINE POWER DERATING MAPACCORDING TO ATMOSPHERIC PRESSURE

ATMOSPHERIC PRESSURE IN kPa

PE

RC

EN

T O

F F

UL

L L

OA

D P

OW

ER

AL

TIT

UD

E IN

FE

ET





J2 J1


ECM



TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESSURE SENSOR (BOOST)





J2 J1


ECM




TURBO OUTLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

OIL

PR

ES

SU

RE

IN k

Pa

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800

ENGINE RPM

OIL PRESSURE MAPOIL PRESSURE WARNING AND DERATE TRIP POINTS

1900

4.4

5.8

14.5

16.0

17.4

18.9

20.3

21.8

23.2

24.7

26.1

27.6

OIL

PR

ES

SU

RE

IN P

SI

kPa x 0.145 = PSI

2000

30

40

50

60

70

80

90

100

0

10

20

140

150

160

170

180

190

110

120

130

0

1.5

2.9

175 kPa (25 psi) RESET LINE

500400

125 kPa (18 psi) RESET LINE

104 kPa (15 psi) TRIP LINE

154 kPa (22 psi) TRIP LINE

2200

7.3

8.7

10.2

11.6

13.1

LOW OIL PRESSURE WARNING

VERY LOW OIL PRESSURE DERATE




J2 J1


ECM




TURBO OUTLET PRESSURE SENSOR


FUEL PRESSURE SENSOR






J2 J1


ECM






HYDRAULIC OIL TEMP. SENSORS

OIL VISCOSITY SELECTION CONNECTOR





J2 J1


ECM






HYDRAULIC OIL TEMP. SENSORS

HYDRAULIC OIL PRESS. SENSORS

• Throttle Position Sensor

DIGITAL SENSORS AND CIRCUITS

• Fan Speed Sensor

J2 J1 ECM

MAINPOWERRELAY KEY

SWITCH

GROUNDBOLT

20 AMPBREAKER

24 V

DISCONNECT SWITCH

20 AMP FUSE

90%

ON

OFF

ON

OFF

ON

OFF

10%

50%

DUTYCYCLE

DUTY CYCLE = PERCENT OF TIME ON VS PERCENT OF TIME OFF

1 CYCLE

= 90%

DUTYCYCLE

= 50%

DUTYCYCLE

= 10%

PULSE WIDTH MODULATED SIGNALS

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

2

P1 J1GROUND LEVEL

SHUTDOWN SWITCH

82 9

ECM

2

1

3

GROUND LEVEL SHUTDOWN SWITCH CIRCUIT

USER DEFINED SHUTDOWN59

P1 J1

USER SHUTDOWNDEVICE 5 DIGITAL RETURN

ECM

USER DEFINED SHUTDOWN CIRCUIT

24V

12

BAAIR INTAKE

HEATER RELAY

AIR INTAKEHEATER LAMP

J501 P501

J648

P648

850-BU 1 AIR INTAKEHEATER RELAY

ECM

AIR INTAKE HEATER CIRCUIT

AIR INTAKEHEATER

CAT DATA LINK

J2 J1

CATELECTRONIC TECHNICIAN

ENGINEELECTRONIC CONTROL

MODULE (ECM) LAPTOPCOMPUTER

SERVICETOOL

CONNECTOR

160-0141SERIAL CABLE

(25 FT.)

160-0133UNIVERSALDATA LINK

CABLE (2 FT.)

COMMUNICATIONADAPTER II

171-4400 (GP)

PC SERIAL PORT(COMM PORT)

CATERPILLAR MONITORING SYSTEMDISPLAY UNIT

TRANSMISSIONELECTRONIC CONTROL

MODULER

0

5

1015

20

25

30

P

X100

24 V MPHkm/h

44

AUT

706542 8 93450

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

P1 J1 ENGINE ECM

ABCDEFG

SERVICE TOOLCONNECTOR

J63

87


87


TRANSMISSION ECMCATERPILLAR

MONITORING SYSTEM

TYPICAL CAT / CAN DATA LINK CIRCUIT

Motor C9 Sistemas

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