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CCCC----9999 EEEENNNNGGGGIIIINNNNEEEESSSSYYYYSSSSTTTTEEEEMMMMSSSS AAAANNNNDDDD CCCCOOOONNNNTTTTRRRROOOOLLLLSSSS
© 2001 Caterpillar Inc.
123456
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)
1234567
123456
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
ANALOG SENSOR POWER (+5V) 1
J209/P20918 FUEL PRESSURE SIGNAL
CBA
ATMOSPHERIC PRESSURE SIGNALANALOG SENSOR RETURN 1
ANALOG SENSOR POWER (+5V) 1
J203/P2031432
CBA
HYDRAULIC OIL PRESSURE SIGNALANALOG SENSOR RETURN 1
ANALOG SENSOR POWER (+5V) 1
J204/P2044027
TURBO OUTLET PRESSURE SIGNALHYDRAULIC OIL PRESSURE SIGNAL
CBA
TURBO OUTLET PRESSURE SIGNALANALOG SENSOR RETURN 3
ANALOG SENSOR POWER (+5V) 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
CAT DATA LINK +CAT DATA LINK -
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
6 COMPRESSIONBRAKE SOLENOIDS
ECM
6 INJECTOR SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
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
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
COOLANT TEMP. SENSOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
AIR INTAKE TEMP. SENSOR
COOLANT TEMP. SENSOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
AIR INTAKE TEMP. SENSOR
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
COOLANT TEMP. SENSOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO INLET PRESSURE SENSOR
TURBO OUTLET PRESSURE SENSOR (BOOST)
COOLANT TEMP. SENSOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO INLET PRESSURE SENSOR
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
COOLANT TEMP. SENSOR
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO INLET PRESSURE SENSOR
TURBO OUTLET PRESSURE SENSOR
ENGINE OIL PRESSURE SENSOR
FUEL PRESSURE SENSOR
ENGINE SPEED/TIMINGSENSORS
COOLANT TEMP. SENSOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
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
COOLANT TEMP. SENSOR
ENGINE SPEED/TIMINGSENSORS
TIMING CALIBRATION CONNECTOR
6 INJECTOR SOLENOIDS
J2 J1
6 COMPRESSIONBRAKE SOLENOIDS
ECM
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
• 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
CAT DATA LINK +CAT DATA LINK -
87
CAT DATA LINK +CAT DATA LINK -
TRANSMISSION ECMCATERPILLAR
MONITORING SYSTEM
TYPICAL CAT / CAN DATA LINK CIRCUIT
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