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C-9 HEUI
SYSTEM POWER SUPPLIES

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

18

SYSTEM POWER SUPPLIES

Introduction

• Seven system power The C-9 HEUI system has seven power supplies with various voltages as
supplies shown.

EXTERNAL POWER SUPPLY

ECM power supply (machines) 24 Volts
Challenger Tractors and some industrial engines 12 Volts
Air intake heater (machines) 24 Volts
Service Tool Power Supply 24 Volts

INTERNAL POWER SUPPLIES

Injector and compression brake power supplies 70 Volts
Pump control valve PWM
Analog sensor power supply 5 Volts
Digital sensor power supply 8 Volts

These power supplies are described in detail in the following section.

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J2 J1 ECM

GROUND
6 DRIVERS BOLT

DISCONNECT SWITCH
3 RETURNS 24 V

ENGINE RETARDER 20 AMP FUSE

SOLENOIDS 20 AMP
BREAKER
MAIN
TIMING CALIBRATION POWER
CONNECTOR KEY START
RELAY
SWITCH

CRANK WITHOUT INJECT PLUG

19

ECM Power Supply

• 24 Volt power supply The power supply to the ECM and the system is provided by the 24 Volt
machine battery. The principle components in this circuit are:

• Power supply - Battery

components - Key Start Switch
- Main Power Relay
- 20 Amp Breaker
- 20 Amp Fuse
- Ground Bolt
- ECM Connector (P1/JI)

• Power supply
If the supply voltage exceeds 32.5 Volts or is less than 9.0 Volts, a
diagnostic message diagnostic message is logged. (See the Troubleshooting Guide for
complete details on voltage event logging.)
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ECM POWER SUPPLY CIRCUIT

BATTERY ENGINE BLOCK

GROUND BOLT P1 J1 ECM (C-9)
(-) 61 (-) BATTERY
63 (-) BATTERY
24 VOLTS DC
65 (-) BATTERY
(+) 20 A 48 (+) BATTERY
52 (+) BATTERY
DISCONNECT FUSE
53 (+) BATTERY
SWITCH
70 (+) SWITCHED POWER
WIRE FUNCTION COLOR CODE
(+) BATTERY SUPPLY WIRES
INPUT SIGNAL WIRES TO ECM
R
OUTPUT SIGNAL WIRES FROM ECM
15 AMP C OFF
SENSOR SUPPLY VOLTAGE
CIRCUIT BREAKER S ON
SIGNAL PLUS
B ST
SIGNAL MINUS
KEY SWITCH
(-) BATTERY / SENSOR RETURN

20

• ECM power supply This schematic shows the principle components for a typical C-9 ECM
circuit power supply circuit. Battery voltage is normally connected to the ECM.
However, an input from the key start switch turns the ECM ON.

Note the seven power connections on the ECM. There are three wires
permanently connected to the ECM battery positive and three to the
battery negative. This feature is used to reduce the amperage on the
individual pins. The actual current draw with the engine stopped and with
the key off is very small.

There is also a switched connection from the battery positive (ECM

• ECM switched
pin 70). The purpose of the "switched power" connection is to energize or
connection
- Energizes ECM
"wake up" the ECM. The key switch circuit energizes the whole ECM
from "sleep mode," which in turn activates power supplies, sensors,
actuators, injectors, data links etc.
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• Battery disconnect The battery disconnect may be either on the positive or the negative cable
switch depending on the application. The relevant Troubleshooting Guide will
show the location and the polarity of the switch.
• Wiring harness The machine wiring harness can be bypassed for troubleshooting
bypass
purposes. These steps are described in the Troubleshooting Guide
procedure. A breakout harness can be used and is referenced under "C-9
Recommended Tooling" at the front of this book.

The system supply voltage may be conveniently checked using the ET

Status Screen display.

NOTE 1: The Challenger Tractor engine and some industrial engines

may have a 12 Volt power supply.

NOTE 2: The Wire Function Color Code is shown here for the first time
and is used through the presentation.
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ECM CONNECTOR (P1)

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

ECM SIDE HARNESS SIDE

21

There are two 70 pin connectors which identify the ADEM III ECM. The
previous ADEM II ECM used a pair of 40 pin connectors.

• P1/P2 70 pin ECM The 70 pin ECM connectors are vital parts of all the power supplies (and
connectors sensor circuits). This illustration shows one of the two ECM 70 pin
connectors, P1. The pins highlighted in this connector are for the ECM
power supply circuit.

• P1/J1 machine Some C-9 Engines may have a separate machine interface connector. The
interface connector P1/J1 connector performs this function and transmits the power supply
from the machine wiring to the engine wiring harnesses. OEM circuits
pass through this connector.

The Troubleshooting Guide identifies the relevant pins for each circuit in
this manner. This feature greatly simplifies troubleshooting by easily
identifying the connections in the circuit.
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INJECTOR AND COMPRESSION BRAKE

SOLENOID CIRCUITS
2 12 20 BRAKE RETURN CYL 1
1 1 36 INJECTOR/BRAKE CYL 1
18 44 INJECTOR RETURN CYL 1
2 11 21 BRAKE RETURN CYL 2
BRAKE 1 2 37 INJECTOR/BRAKE CYL 2
SOLENOID 17 45 INJECTOR RETURN CYL 2
CYL. 1 2 10 28 BRAKE RETURN CYL 3
BRAKE 1 3 38 INJECTOR/BRAKE CYL 3
SOLENOID 16 46 INJECTOR RETURN CYL 3
J301 P301 CYL. 2 2 9 29 BRAKE RETURN CYL 4
1 BRAKE 1 4 39 INJECTOR/BRAKE CYL 4
2 SOLENOID 15 47 INJECTOR RETURN CYL 4
J302 P302 CYL. 3 2 8 65 BRAKE RETURN CYL 5
1 BRAKE 1 5 54 INJECTOR/BRAKE CYL 5
2 J303 P303 SOLENOID 14 67 INJECTOR RETURN CYL 5
CYL. 4 2 7 66 BRAKE RETURN CYL 6
1
2 BRAKE 1 6 55 INJECTOR/BRAKE CYL 6
J304 P304 SOLENOID 13 68 INJECTOR RETURN CYL 6
CYL. 5
1 BRAKE P300 J300 P2 J2 ECM
2 SOLENOID
J305 P305 CYL. 6
INJECTOR 1
SOLENOID 2 J306 P306
CYL. 1 1
INJECTOR 2
SOLENOID
CYL. 2 INJECTOR
SOLENOID
CYL. 3
INJECTOR
SOLENOID
CYL. 4
INJECTOR
SOLENOID
CYL. 5
INJECTOR
SOLENOID
CYL. 6

22

Injector and Compression Brake Power Supply

• 70 volt power supply The injector and compression brake solenoids are supplied with power
from the ECM at 70 Volts. For this reason, precautions must be observed
when performing maintenance around the valve covers.

If an open or a short circuit occurs in an injector or compression brake

component, the ECM will disable that circuit. The ECM will periodically
try to actuate that circuit to determine if the fault is still present and will
disconnect or reconnect the injector/compression brake as appropriate.

• Power supply wires The power supply wires are paired for each injector and brake solenoid.
are paired Individual return circuits are provided which contain the solenoid drivers.
An 18 pin (P300/J300) connector is used to connect the main engine
• Injectors and brake wiring harness to the injector harness within the valve cover.
solenoids are
switched on return NOTE: If an injector is replaced, it must be calibrated. Also if an
side ECM is replaced and injector calibration or copy configuration is not
performed, a fault message will be generated. (The Copy
Configuration function will transfer all calibrations to the new ECM.)
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PUMP CONTROL VALVE

POWER SUPPLY

PUMP CONTROL
VALVE J500 P500
P2 J2 ECM (C-9 HEUI)
SUPPLY A 61 + CONTROL VALVE
RETURN B 62 - CONTROL VALVE

23

Hydraulic Pump Control Valve Power Supply

• Pump control valve The ECM supplies a PWM signal through the J2/P2 connector to the
signal Pump Control Valve (also known as the injection actuation pressure
control valve).

• System tested using The Pump Control Valve and its power supply can be tested on the engine
ET using ET and the Hydraulic Injection Actuation Pressure Test. Using the
test, the pressure can be adjusted manually with the ET service tool from
minimum to maximum. Therefore, this function can be used to verify the
operation of the control valve, the power supply from the ECM, and the
hydraulic system.

• ET used to check The actual current flow can be read as a percentage of maximum using the
current flow ET Status Screen.

There is no voltage specification for the Pump Control Valve Power

Supply. Current flow may vary between 250 and 1000 mA.
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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

24

Analog Sensor Power Supply

• Analog power supply The Analog Sensor Power Supply provides power to all the active analog
sensors (pressure and temperature sensors). The ECM supplies 5.0 ± 0.5
Volts DC (Analog Supply) through the J2/P2 connector to each sensor. A
power supply failure will cause all active analog sensors to fail. This
failure could be caused by a short in a sensor. An open circuit in the
common lines close to the P2/J2 connector can also cause multiple
• Four power supply failures. Unlike previous EUI/HEUI engines, the C-9 uses four individual
terminals ECM analog power connections from the J1/P1 connector (two supply
and two return).
• Power supply The Analog Sensor Power Supply is protected against short circuits. A
protection short in a sensor or a wiring harness will not cause damage to the ECM.
• Analog return NOTE: When checking the analog power supply voltage, always use
the analog return (at the power supply) for the measurement and not
the frame ground. A difference can occur between the measurements
of analog power supply and system voltage. The analog power supply
is held to close tolerances.
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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

FAN DIGITAL SENSOR

SPEED SENSOR POWER SUPPLY CIRCUIT
+V DIGITAL A 8 ± 0.5 VOLTS
DIGITAL RETURN B
SIGNAL C

25

Digital Sensor Power Supply

• Digital power supply The ECM supplies power at 8 ± 0.5 Volts through the J1/P1 connector to
the Throttle Position Sensor circuit.

• Power supply Like the Analog power supply, this circuit is protected against short
protection circuits, which means that a short in the sensor will not cause damage to
the ECM.

Some other C-9 applications may use this power supply to power fan
speed or exhaust temperature sensors for example.

• Digital power supply NOTE: It is necessary when checking this system power supply
voltage check voltage to use the digital return for the measurement and not the
frame ground. A difference between these values can occur if an
• Digital return
incorrect ground is used.
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AIR INTAKE HEATER CIRCUIT

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

26

Air Intake Heater

The Air Intake Heater is used to improve the cold start ability of the
engine.

• Uses coolant and The heater is controlled by the ECM using inputs from the Air Intake
intake temperature Temperature and Coolant Temperature Sensors. The ECM sends a signal
sensors as references to the relay which controls the supply of current to the heater element.

• Modes of operation There are a various modes of operation depending on temperatures and
other conditions. These parameters and the defaults are fully described in
the C-9 Troubleshooting Guide and later in this presentation in the section
"Electronic Sensors and Systems."
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TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT

CATERPILLAR
TRANSMISSION ECM MONITORING SYSTEM

R CAT DATA LINK + 8 8 CAT DATA LINK +

CAT DATA LINK - 7 7 CAT DATA LINK -
OFF C
ON S
ST B
J63 P1 J1 ENGINE ECM
KEY SWITCH A 70 BAT + (SWITCHED)
B 65 BAT -
C
D 8 CAT DATA LINK +
E 9 CAT DATA LINK -
DATA LINKS
F 34 CAN DATA LINK -
G 50 CAN DATA LINK +
SERVICE TOOL
CONNECTOR

27

Service Tool Power Supply

• Communication
In the past, the ECAP (Electronic Analyzer Programmer) Service Tool
adapter uses power drew it's power from the Service Tool Connector. In the same way, when
from ECM using ET, the Communicator Adapter II also requires a power supply.
This power is taken from pins A and B on the Service Tool Connector.

• Circuit is energized This illustration shows the path of the current from the ECM Key Switch
with the Key Switch Circuit to the Service Tool Connector. This power supply requires the
engine Key Switch to be ON.

Pin 70 on the J1/P1 connector, is the same terminal which is used by the
Key Switch to turn on the ECM.
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LAB EXERCISE

INSTRUCTOR NOTE: The following exercises will reinforce the

material introduced in the preceding pages and will allow questions to be
answered.

• Lab exercise Lab Exercise:

Remove and install the following components on an engine in accordance

with the appropriate Service Manual procedures:

Pressure sensor

Temperature sensor

Throttle position sensor

Speed/timing sensors

ECM

Test the following power supply circuits on an engine in accordance with

the appropriate Service Manual procedures:

ECM power supply

HEUI pump control valve power supply

Analog sensor power supply

Digital sensor power supply

Air intake heater power supply

Service tool power supply

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INSTRUCTOR NOTES
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