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INLET
VALVES FIRING ORDER 1 5 3 6 2 4
6 5 4 3 2 1
EXHAUST
MANIFOLD INTAKE AIR TO AIR
HEATER AFTERCOOLER
AIR EXHAUST
INLET OUTLET
OIL
COMPRESSOR OUTLET
WHEEL BEARING 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
CYLINDER BYPASS
BLOCK HOSE
OIL WATER
COOLER PUMP RADIATOR
CRANKSHAFT OIL FLOW
OIL GALLERY
MAIN
BEARINGS
(7)
7 6 5 4 3 2 1
6 5 4 3 2 1
ROD BEARINGS (6)
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
6 DRIVERS BOLT
DISCONNECT SWITCH
3 RETURNS 24 V
1 2 3 4 5 6 8 9 10 11 12 13
13 1
23 14 14 >PEI< 23
31 24
24 31
39 32 36
47 40 40 47
57 48 48 57
70 58
58 59 60 61 62 63 65 66 67 68 69 70
PUMP CONTROL
VALVE J500 P500
P2 J2 ECM (C-9 HEUI)
SUPPLY A 61 + CONTROL VALVE
RETURN B 62 - CONTROL VALVE
ANALOG SENSOR
J200/P200
POWER SUPPLY CIRCUIT
TURBO OUTLET PRESSURE SIGNAL C 5 ± 0.5 VOLTS
ANALOG SENSOR RETURN 3 B
ANALOG SENSOR POWER (+5V) 3 A
P2 J2 ECM
J204/P204
HYDRAULIC OIL PRESSURE SIGNAL C 40 TURBO OUTLET PRESSURE SIGNAL
ANALOG SENSOR RETURN 1 B 27 HYDRAULIC OIL PRESSURE SIGNAL
ANALOG SENSOR POWER (+5V) 1 A
J203/P203
ATMOSPHERIC PRESSURE SIGNAL C 14 ATMOSPHERIC PRESSURE SIGNAL
ANALOG SENSOR RETURN 1 B 3 ANALOG SENSOR RETURN 1
ANALOG SENSOR POWER (+5V) 1 A 2 ANALOG SENSOR POWER (+5V) 1
J209/P209
FUEL PRESSURE SIGNAL C 18 FUEL PRESSURE SIGNAL
ANALOG SENSOR RETURN 1 B
ANALOG SENSOR POWER (+5V) 1 A
J201/P201
ENGINE OIL PRESSURE SIGNAL C 24 ENGINE OIL PRESSURE SIGNAL
ANALOG SENSOR RETURN 3 B 42 ANALOG SENSOR RETURN 3
ANALOG SENSOR POWER (+5V) 3 A 41 ANALOG SENSOR POWER (+5V) 3
THROTTLE
POSITION SENSOR J405 P405 P1 J1 ECM (C-9 HEUI)
+V DIGITAL A 4 + V DIGITAL SUPPLY
DIGITAL RETURN B 5 - V DIGITAL RETURN
SIGNAL C
AIR INTAKE
HEATER LAMP
24V
J648
A
B
P648
AIR INTAKE AIR INTAKE
HEATER HEATER RELAY
J501/P501 ECM
1 J2/P2
2 AIR INTAKE
850-BU 12 HEATER RELAY
TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT
CATERPILLAR
TRANSMISSION ECM MONITORING SYSTEM
TIMING CONTROL
ENGINE SPEED TIMING DEGREES BTDC DESIRED
TIMING FUEL INJECTION
FUEL QUANTITY FUEL RPM
BTDC CONVERT TIMING WAVE FORM
SELECT
TIMING DESIRED
HYDRAULIC OIL TIMING
TEMPERATURE
C-9
ELECTRONIC HYDRAULIC OIL
GOVERNOR SHUTDOWNS TEMPERATURE AND
PRESSURE SENSORS
ECM
TO PUMP
CONTROL ELECTRONIC
VALVE GOVERNOR
6
5
SIGNALS 4 FUEL AFRC TORQUE ENGINE THROTTLE
TO FUEL 3 INJECTION ENGINE RPM MAPS MAPS CONTROL
INJECTORS 2 CONTROL LOGIC
1 TDC
LOWER
SPEED/TIMING SENSOR B
(600 TO 1800 OHMS)
SENSOR A
CAMSHAFT MEASURED TDC NO.1 45° CRANK
IDLER
SENSOR B
GEAR LOWER SENSOR UPPER SENSOR
MEASURED TDC NO.1
LOW SPEED HIGH SPEED
15° CRANK 30° CRANK
CRANKSHAFT
GEAR GEAR
ROTATION
SENSOR
SIGNALS
UPPER SENSOR A TIMING -90° -60° -30° 0° 30° 45° 60° 90°
LOWER SENSOR B TIMING -70° -45° -15° -0° 15° 45° 75° 90° 105°
C-9 TIMING CALIBRATION
PROBE INSTALLATION
TDC POSITION
CRANKSHAFT
COUNTERWEIGHT
MACHINED FACE
DIRECTION OF
ROTATION
TIMING
WHEEL
-3° +3°
TIMING REFERENCE
TIMING CALIBRATION
OFFSET
SENSOR SIGNAL
(MAXIMUM RANGE
± 3 DEGREES)
25 ENGINE DEGREES
C-9 SPEED/TIMING SENSORS CALIBRATION
UPPER (HIGH SPEED)
SPEED/TIMING
SENSOR J401/P401
1
2 J2/P2 ECM
TIMING CALIBRATION
PROBE J400/P400
1 22 + TIMING CAL PROBE
2 23 - TIMING CAL PROBE
TIMING CALIBRATION
CONNECTOR
ELECTRONIC SENSORS
AND
SYSTEMS
ECM J2 J1
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
ECM J2 J1
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
TIMING CALIBRATION
CONNECTOR
ECM J2 J1
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
ENGINE SPEED/TIMING
SENSORS
ANALOG SENSORS
• Hydraulic oil temperature
• Lubrication oil pressure
• Air intake temperature
• Atmospheric pressure
• Hydraulic oil pressure
• Turbocharger outlet pressure
• Coolant temperature
ECM J2 J1
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
ENGINE SPEED/TIMING
SENSORS
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
ENGINE SPEED/TIMING
SENSORS
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
ENGINE SPEED/TIMING
SENSORS
8,210
PERCENT OF FULL LOAD POWER
98%
96% 8,920
94% 9,630
10,340
ALTITUDE IN FEET
92%
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
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
ENGINE SPEED/TIMING
SENSORS
6 COMPRESSION
BRAKE SOLENOIDS
ENGINE SPEED/TIMING
SENSORS
170 24.7
160 23.2
120 17.4
110 16.0
90 13.1
80 11.6
70 10.2
50 7.3
VERY LOW OIL PRESSURE DERATE
40 5.8
30 4.4
20 2.9
10 1.5
0 0
400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2200
ENGINE RPM
kPa x 0.145 = PSI
ECM J2 J1
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
TIMING CALIBRATION
CONNECTOR
ENGINE SPEED/TIMING
SENSORS
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
TIMING CALIBRATION
CONNECTOR
ENGINE SPEED/TIMING
SENSORS
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
TIMING CALIBRATION
CONNECTOR
ENGINE SPEED/TIMING
SENSORS
24 V
20 AMP FUSE
20 AMP
BREAKER
MAIN
POWER
RELAY KEYSWITCH
PULSE WIDTH MODULATED SIGNALS
10% LOW IDLE 0% THROTTLE
ON
DUTY = 10%
CYCLE
OFF
50% MID RANGE SPEED 50% THROTTLE
ON
DUTY = 50%
CYCLE
OFF
1 CYCLE
90% FULL SPEED / HIGH IDLE 100% THROTTLE
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 P1 J1 ECM
1
2 GND. LEVEL SHUTDOWN (NO)
2
8 GND. LEVEL SHUTDOWN (NC)
3 29 DIGITAL RETURN
USER DEFINED SHUTDOWN CIRCUIT
P1 J1
ECM
AIR INTAKE
HEATER LAMP
24V
J648
A
B
P648
AIR INTAKE AIR INTAKE
HEATER HEATER RELAY
J501/P501 ECM
1 J2/P2
2 AIR INTAKE
850-BU 12 HEATER RELAY
CAT DATA LINK
UNIVERSAL
DATA LINK SERIAL CABLE
CABLE (2 FT.) (25 FT.)
J2 J1
PC SERIAL PORT
(COMM PORT)
SERVICE
COMMUNICATION
TOOL
ADAPTER II
ENGINE CONNECTOR CAT
171-4400 (GP) ELECTRONIC TECHNICIAN
ELECTRONIC CONTROL
MODULE (ECM) LAPTOP
COMPUTER
P
15 AUT
10 20
TRANSMISSION 5
25
ELECTRONIC CONTROL R
X100
0 44
MODULE 24 V
MPH
km/h
30