Service Training: C-9 Engine Systems and Controls

SERH4050-01
April 2004
SERVICE TRAINING
STUDENT MATERIALS
C-9 ENGINE
SYSTEMS AND CONTROLS
SERH4050 -2- Student Materials
4/04
CONTENTS
TOOLING LIST
LAB A: C-9 SYSTEMS COMPONENT IDENTIFICATION
LAB B: C-9 SYSTEMS OPERATION
LAB C: FUEL INJECTION SYSTEM COMPONENT REMOVAL AND INSTALLATION
LAB D: FUEL INJECTION SYSTEM TESTING AND ADJUSTING
LAB E: ELECTRICAL/ELECTRONIC COMPONENT REMOVAL AND INSTALLATION
LAB F: ELECTRONIC SYSTEM POWER SUPPLY TESTING
LAB G: ELECTRICAL/ELECTRONIC COMPONENT TESTING AND ADJUSTING
LAB H: GENERAL SYSTEM DIAGNOSTICS

SERH4050 -3- Laboratory Exercises
4/04
TOOLING LIST
RECOMMENDED C-9 ENGINE TOOLING

Software and Manuals
Caterpillar Service Technician Workbench
Getting Started Guide - NEHS0796
or Electronic Technician Software CD and
Getting Started Book JEBD3003
Communication Adapter II User's Manual NEHS0758
Mechanical Tools
C-9 Tool Kit (contains all C-9 special tools) 196-3165
Engine Turning Tool 9S-9082
Engine Turning Tool (for tractors) 208-0888
Electronic Tools
Laptop computer
Communication Adapter II (Group) 171-4400
Cable, PC to Communication Adapter 196-0055
Cable, Communication Adapter to Machine 207-6845
Caterpillar Digital Multimeter 146-4080
Three Pin DT Breakout Harness 7X-6370
Cable Probes 7X-1710
Auxiliary ECM Power Supply Harness 167-9225
Timing Calibration Probe (Magnetic Pickup) 6V-2197
Timing Calibration Probe Adapter Sleeve 7X-1171
Timing Calibration Probe Cable 7X-1695
4/04
Lab A: C-9 Systems Component Identification
EXERCISE Shop Exercise:

Using the lab worksheets and the system schematics, identify components
for the following systems where visible:
- Cooling System
- Lubrication System
- Air Intake and Exhaust System
- Fuel Delivery System
- Fuel Control System
After component identification, state the function and location of each

component listed on the worksheet either written or orally. All engine
locations are referenced from the rear of the engine.
C-9 engine or
Machine or truck with C-9 engine
Cooling, lubrication, air intake and exhaust system schematics
Lab A Worksheets
4/04
Lab A: C-9 Engine Component Identification
COOLING SYSTEM
Thermostat and Housing

Function:
Location:
Coolant Temperature Sensor

Function:
Location:
Water pump
Function:
Location:
Bypass Line
Function:
Location:
4/04
LUBRICATION SYSTEM
Oil pressure Sensor

Function:
Location:
Oil pump
Function:
Location:
Oil filter
Function:
Location:
Oil cooler
Function:
Location:
Oil breather
Function:
Location:
4/04
AIR INTAKE AND EXHAUST SYSTEM
Atmospheric Pressure Sensor

Function:
Location:
Intake Manifold Pressure Sensor

Function:
Location:
Intake Manifold Heater and Relay

Function:
Location:
Turbocharger Compressor
Function:
Location:
Turbocharger Turbine
Function:
Location:
Wastegate (if equipped)

Function:
Location:
4/04
FUEL DELIVERY SYSTEM
Transfer Pump
Function:
Location:
Priming Pump
Function:
Location:
Primary Filter and Water Separator

Function:
Location:
Secondary Filter
Function:
Location:
Unit Injector
Function:
Location:
Fuel Pressure Regulating Valve

Function:
Location:
4/04
FUEL DELIVERY SYSTEM
Cylinder Head Fuel Passage

Function:
Location:
ECM Fuel Cooling Passage (if so equipped)

Function:
Location:
FUEL CONTROL SYSTEM
ECM and 70 Pin Connectors

Function:
Location:
HEUI Hydraulic Pump

Function:
Location:
Hydraulic Pump Control Valve (IAPCV)

Function:
Location:
Hydraulic Manifold
Function:
Location:
Hydraulic Pressure Sensor

Function:
Location:
SERH4050 - 10 - Student Materials
4/04
FUEL CONTROL SYSTEM
Hydraulic Oil Temperature Sensors

Function:
Location:
Speed/Timing Sensors
Function:
Location:
Timing Wheel
Function:
Location:
Timing Calibration Probe

Function:
Location:
Throttle Position Sensor

Function:
Location:
Ground Level Shutdown Switch

Function:
Location:
User Defined Shutdown

Function:
Location:
4/04
FUEL CONTROL SYSTEM
CAT Data Link

Function:
Location:
CAN Data Link
Function:
Location:
Service Tool Connector
Function:
Location:
Analog Power Supply
Function:
Location:
Digital Power Supply
Function:
Location:
Ground Stud
Function:
Location:
4/04
Lab B: C-9 Systems Operation
EXERCISE Classroom Exercise:

Using the system schematics, trace the flow through the systems and
identify the following components on the schematics:
Cooling System:
- Thermostat and housing
- Coolant temperature sensor
- Water pump
- Bypass line
Lubrication System:
- Oil pressure sensor
- Oil pump
- Oil filter
- Oil cooler
- Oil breather
Air Intake and Exhaust System:

- Atmospheric pressure sensor
- Turbocharger outlet pressure sensor
- Intake manifold heater and relay
- Air filters
- Turbocharger compressor
- Turbocharger turbine
- Wastegate, if installed
Fuel Delivery System:

- Unit injector
- Transfer pump
- Priming pump
- Primary filter
- Water separator
- Secondary filter
- Fuel pressure regulating valve
4/04
Lab B: C-9 Systems Operation (continued)

Electronic Control System:
- ECM and 70 pin connectors
- Personality module
- Speed/timing sensors
- HEUI hydraulic pump
- Pump control valve
- Hydraulic pressure sensor
- Analog and digital sensors
- Electronic unit injector
- Service tool connector
- Machine interface connector
- System power supplies
- Data links
- Shutdown systems
- System power supplies
- Ground stud
MATERIALS NEEDED The following system schematics are required to complete this lab
exercise.
Air Intake and Exhaust System Schematic
Lubrication System Schematic
Cooling System Schematic
Fuel System Schematic
Electronic System Schematic
4/04
SERH4050
AIR INTAKE AND EXHAUST SYSTEM
EXHAUST
MANIFOLD INTAKE AIR TO AIR
HEATER AFTERCOOLER
- 14 -
INLET AIR EXHAUST

EXHAUST OUTLET
VALVE VALVE INLET
TURBOCHARGER
COMPRESSOR TURBINE
SIDE SIDE
Student Materials
4/04
SERH4050
C-9 LUBRICATION SYSTEM
HEUI PUMP
- 15 -
TO
TURBOCHARGER OIL COOLER
OIL
FILTER
Student Materials
4/04
SERH4050
COOLING SYSTEM
EXPANSION TANK
WATER TEMPERATURE
REGULATOR HOUSING
CYLINDER
HEAD
- 16 -
CYLINDER BYPASS
BLOCK HOSE
OIL WATER
COOLER PUMP RADIATOR
Student Materials
3/04
3/04
INPUTS AND OUTPUTS TO ENGINE ECM
SERH4050
ECM J2 J1
6 INJECTOR SOLENOIDS
6 COMPRESSION
BRAKE SOLENOIDS
TIMING CALIBRATION
CONNECTOR
ENGINE SPEED/TIMING
SENSORS
- 18 -
COOLANT TEMP. SENSOR
AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
ENGINE OIL PRESSURE SENSOR
FUEL PRESSURE SENSOR
HYDRAULIC OIL TEMP. SENSORS
HYDRAULIC OIL PRESS. SENSOR

Student Materials
4/04
Lab C: Fuel Injection System Component Removal and

Installation
Remove and install the following components following Service Manual

procedures:
- Transfer Pump
- Fuel Pressure Regulating Valve
- Primary Filter
- Secondary Fuel Filter
- Hydraulic Unit Injector
- Hydraulic (HEUI) Pump
Note the importance of NOT filling the filter prior to installation.
MATERIALS NEEDED A machine or truck with a C-9 Engine and/or C-9 engine
Fuel Delivery Circuit Schematic and sectional views (refer to
addendum)
PC with ET/STW software installed
Engine Service Manual
Communication Adapter and Cables
Caterpillar Multimeter
Injector removal installation tool
Mechanic's tool box with hand tools
4/04
SERH4050
HEUI FUEL
INJECTORS GALLERY
PRESSURE
REGULATOR
TRANSFER PUMP PRIMARY PRIMING

FILTER PUMP
- 20 -
(10 MICRON)
WATER
SECONDARY
SEPARATOR
FILTER
(2 MICRON) PRIMING PUMP
RELIEF
CHECK VALVES
VALVE
TANK
Student Materials
4/04
Lab D: Fuel Injection System Testing and Adjusting
This lab will verify that the student has the necessary skills to test the
components after removal and installation.
Demonstrate the following:

- Input injector trim codes using ET
- Retrieve Active and Logged Faults for injectors
- Injector Solenoid Test
- Manual Cylinder Cutout Test with no load
- Manual Cylinder Cutout Test with a constant load applied
- Automatic Cylinder Cutout Test
- Cylinder Cutout with torque stall test
- Injector Actuation Pressure Test
MATERIALS NEEDED A machine or truck with a C-9 Engine and/or a C-9 engine
Injector removal installation tool
Lab D Worksheets
4/04
Caterpillar Electronic Technician (Cat ET)
SERH4050
PC To Machine/Engine Connections
Communication Adapter II
ENGINE
ELECTRONIC 207-6845 UNIVERSAL 196-0055 SERIAL CABLE (25 ft) *
CONTROL MODULE (ECM) DATA LINK CABLE (2 ft) or 225-5985 PARALLEL CABLE (25 ft) **
160-0133 (discontinued) 160-0141 SERIAL CABLE (25 ft) *** STW/E
T
To PC SERIAL USB OR
SERVICE TOOL
PARALLEL PORT
CONNECTOR COMMUNICATION
(Comm Port)
ADAPTER II
171-4400 (Group)
Supports ATA CDL & CAN data links 237-7547
USB/SERIAL PORT ADAPTER
- 22 -
* Included with Comm Adapter Group

** For use only on newer PC's without serial ports
*** For all PC's except IBM Think Pads and Compac Computers
ENGINE Communication Adapter I

ELECTRONIC
CONTROL MODULE (ECM) 139-4166 7X1425
DATA LINK CABLE (18 ft) SERIAL CABLE (4 ft) STW/E
T
PC SERIAL OR USB PORT

SERVICE TOOL (COMM PORT)
CONNECTOR
COMMUNICATION
ADAPTER I
7X1700 (Group)
Supports ATA & CDL data links
(discontinued but still in use)
Student Materials
4/04
LAB D: HEUI INJECTOR TEST WORKSHEET

C-9 ENGINE APPLICATION: ENGINE SERIAL NO:
INJECTOR ACTIVE FAULTS
INJECTOR LOGGED FAULTS
INJECTOR TEST
SOLENOID MANUAL CYLINDER AUTO CYLINDER
TEST CUTOUT TEST RPM CUTOUT TEST
COOLANT
CYLINDER OPEN/SHORT/OK NO LOAD FULL LOAD RESULTS
TEMP
RETEST
6
4/04
LAB D: C-9 HYDRAULIC SYSTEM TEST WORKSHEET

C-9 ENGINE APPLICATION:
ENGINE SERIAL NO:
INJECTOR ACTUATION PRESSURE TEST
DESIRED ACTUAL COOLANT

TEST % LOAD RPM % CURRENT
PRESSURE PRESSURE TEMP
MANUAL NO LOW IDLE
MANUAL NO HIGH IDLE
MANUAL FULL FULL LOAD
INJECTOR ACTUATION PRESSURE RETEST
DESIRED ACTUAL COOLANT

TEST % LOAD RPM % CURRENT
PRESSURE PRESSURE TEMP
MANUAL NO LOW IDLE
MANUAL NO HIGH IDLE
MANUAL FULL FULL LOAD

4/04
Lab E: Electrical/Electronic Component Removal and

Installation
Students will remove and install the following components:
- Pressure Sensors
- Temperature Sensor
- Throttle Position Sensor
- Speed/Timing Sensors
- ECM
MATERIALS NEEDED Engine Service Manual

An operable training engine and/or a C-9 powered machine or truck
4/04
Lab F: Electronic System Power Supply Testing

Students will use the procedures provided in the Student Materials to

complete the exercise. Each student should demonstrate competence in
all tasks in this lab.
Test the following power supply circuits following the service manual
procedures:
- ECM power supply
- HEUI pump control valve
- Analog sensor power supply
- Digital sensor power supply
- Air Intake heater power supply
- Service Tool Power Supply
The injector power supply can be verified by the solenoid test or any of
the injector tests.
The pump control valve power supply can be verified using the ET
injection actuation pressure test. Other method use use the status screen
and check the current flow through the solenoid or a VOM.
MATERIALS NEEDED Service literature (see Preparation Checklist)

Lab F Worksheet
4/04
LAB F: POWER SUPPLY TEST WORKSHEET
C-9 ENGINE APPLICATION
ENGINE SERIAL NO:
POWER SUPPLY ACTIVE FAULTS
POWER SUPPLY LOGGED FAULTS
POWER SUPPLY VOLTAGE CHECKS
SPEC ACTUAL
POWER SUPPLY TEST RESULTS
VOLTAGE VOLTAGE
MIN
ECM
MAX
ANALOG MIN
MAX
DIGITAL MIN
MAX
INTAKE MIN
HEATER MAX
SERVICE MIN
TOOL MAX
ANALYSIS
4/04
Lab G: Electrical/Electronic Component Testing and

Adjusting

complete the exercise.
Each student should demonstrate competence in all tasks in this lab.
Students will perform a diagnostic test on the following components:

- Pressure Sensors (perform calibration using two methods)
- Temperature Sensor
- Throttle Position Sensor
- Speed/Timing Sensors (perform calibration)
- ECM (program with new personality module flash file)
MATERIALS NEEDED Engine Service Manual

Lab G Worksheets
4/04
LAB G: ANALOG SENSOR TEST WORKSHEET
ENGINE SERIAL NO:
SENSOR ACTIVE FAULTS
SENSOR LOGGED FAULTS
PRESSURE SENSOR TEST
ABSOLUTE SIGNAL POWER

SENSOR SUPPLY RESULTS
PRESSURE VOLTS
VOLTS
ATMOSPHERIC
INTAKE
MANIFOLD
LUBE OIL
HYDRAULIC
OIL
TEMPERATURE SENSOR TESTS
TEMPERATURE
SENSOR TEST RESULTS
READING
COOLANT
OIL
INLET AIR
4/04
LAB G: DIGITAL SENSOR TEST WORKSHEET
ENGINE SERIAL NO:
DIGITAL SENSOR TEST
POWER
% THROTTLE % DUTY SIGNAL SIGNAL
SENSOR SUPPLY
POSITION CYCLE FREQUENCY VOLTS
VOLTS
THROTTLE
POSITION
LOW IDLE
THROTTLE
POSITION
MIDRANGE
THROTTLE
POSITION
HIGH IDLE
TEST
RESULTS
4/04
LAB G: SPEED/TIMING SENSOR TEST WORKSHEET
ENGINE SERIAL NO:
SPEED/TIMING SENSOR TEST

VOLTS VOLTS
CRANKING RPM ENGINE ENGINE RESULTS
SENSOR
INDICATION STOPPED RUNNING
UPPER
LOWER
TIMING CALIBRATION
SPEED/TIMING SENSORS CALIBRATED
LIST ACTIVE FAULTS (if any)

4/04
LAB G: REMOVE AND REPLACE ECM
INSTRUCTION RESULTS
ENGINE SERIAL NO:
ECM PART NO.
FLASH FILE PART NO. (ORIGINAL)
FLASH FILE PART NO. (LATEST)
COPY CONFIGURATION
FLASH ECM WITH LATEST FLASH FILE
CHECK ACTIVE AND LOGGED FAULTS
PERFORM ENGINE FUNCTIONAL TEST
CHECK ACTIVE AND LOGGED FAULTS
PERFORM ENGINE ANALYSIS

4/04
Lab H: General System Diagnostics


complete the exercises.
The purpose of this lab is to evaluate the student's ability to identify the
source of low power and failure to start problems and to determine
whether the fault is in the electronics or the mechanical parts of the HEUI
system.
Each student should demonstrate competence in all tasks in this lab.
Students will perform diagnostic evaluations on the following circuit

conditions/faults:
- Coolant temperature open or short

- Oil pressure signal open
- Low hydraulic pressure
- Injector open or short
- Analog sensor power supply fault
- Air Intake Manifold (turbo outlet) pressure sensor fault
MATERIALS NEEDED C-9 powered machine or truck

Communication Adapter Group
Lab H Worksheets
4/04
LOW POWER OR FAILURE TO START COMPLAINTS
Review the low power or failure to start diagnostic procedures in the Troubleshooting Guide before
conducting the lab.
The first task is to determine the source of the problem (machine/ truck or engine). Then, if the problem
is in the engine, determine if it is electronic or mechanical.
A number of checks can identify if the engine is, or is not, the root cause:
- Actual engine rpm and desired engine speed.

- Caterpillar Monitoring System Check Engine Lamp for HEUI system faults.
- Derate for Automatic Altitude Compensation.
- Air/Fuel Ratio Control derate.
- Check boost at full power and compare with normal boost in similar conditions.
- Check "fuel" position (synonymous with rack) on ET and compare with rated fuel.
At the end of the session, students should describe why the engine has a low power problem or failure to
start problem with each of the above faults.
4/04
LAB H: NO START SYSTEM DIAGNOSTIC WORKSHEET
ENGINE SERIAL NO:
CHECK LIST (TROUBLESHOOTING GUIDE)
NO. TEST (P-301) RESULT CORRECTION
10
11
12
4/04
LAB H: LOW POWER DIAGNOSTIC WORKSHEET
ENGINE SERIAL NO:
CHECK LIST (TROUBLESHOOTING GUIDE)
NO. TEST (P-301) RESULT CORRECTION
10

Service Training: C-9 Engine Systems and Controls

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Training: C-9 Engine Systems and Controls

Uploaded by

Copyright:

Available Formats

SERH4050-01

LAB A: C-9 SYSTEMS COMPONENT IDENTIFICATION

LAB B: C-9 SYSTEMS OPERATION

LAB C: FUEL INJECTION SYSTEM COMPONENT REMOVAL AND INSTALLATION

LAB D: FUEL INJECTION SYSTEM TESTING AND ADJUSTING

LAB E: ELECTRICAL/ELECTRONIC COMPONENT REMOVAL AND INSTALLATION

LAB F: ELECTRONIC SYSTEM POWER SUPPLY TESTING

LAB G: ELECTRICAL/ELECTRONIC COMPONENT TESTING AND ADJUSTING

LAB H: GENERAL SYSTEM DIAGNOSTICS

RECOMMENDED C-9 ENGINE TOOLING

Lab A: C-9 Systems Component Identification

EXERCISE Shop Exercise:

After component identification, state the function and location of each

Lab A: C-9 Engine Component Identification

Thermostat and Housing

Coolant Temperature Sensor

Lab A: C-9 Engine Component Identification

Oil pressure Sensor

Lab A: C-9 Engine Component Identification

AIR INTAKE AND EXHAUST SYSTEM

Atmospheric Pressure Sensor

Intake Manifold Pressure Sensor

Intake Manifold Heater and Relay

Wastegate (if equipped)

Lab A: C-9 Engine Component Identification

FUEL DELIVERY SYSTEM

Primary Filter and Water Separator

Fuel Pressure Regulating Valve

Lab A: C-9 Engine Component Identification

FUEL DELIVERY SYSTEM

Cylinder Head Fuel Passage

ECM Fuel Cooling Passage (if so equipped)

FUEL CONTROL SYSTEM

ECM and 70 Pin Connectors

HEUI Hydraulic Pump

Hydraulic Pump Control Valve (IAPCV)

Hydraulic Pressure Sensor

Lab A: C-9 Engine Component Identification

FUEL CONTROL SYSTEM

Hydraulic Oil Temperature Sensors

Timing Calibration Probe

Throttle Position Sensor

Ground Level Shutdown Switch

User Defined Shutdown

Lab A: C-9 Engine Component Identification

FUEL CONTROL SYSTEM

CAT Data Link

Lab B: C-9 Systems Operation

EXERCISE Classroom Exercise:

Air Intake and Exhaust System:

Fuel Delivery System:

Lab B: C-9 Systems Operation (continued)

AIR INTAKE AND EXHAUST SYSTEM

INLET AIR EXHAUST

C-9 LUBRICATION SYSTEM

COOLANT TEMP. SENSOR

AIR INTAKE TEMP. SENSOR

ATMOSPHERIC PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

HYDRAULIC OIL PRESS. SENSOR

Lab C: Fuel Injection System Component Removal and