Motor C9 Sistemas

(1)

C

--

_--

9

9 ₉

₉

E

_E

N

_N

G

_G

II

_II

N

_N

E

_E

S

Y

_Y

S

_S

T

_T

E

_E

M

_M

S

_S

A

_A

N

_N

D

_D

C

_C

O

_O

N

_N

T

_T

R

_R

O

_O

L

_L

S

_S

© 2001 Caterpillar Inc.

(2)

1

2

3

4

5

6 EXHAUST

VALVES

INLET

VALVES

CYLINDER AND VALVE LOCATION

FIRING ORDER 1 5 3 6 2 4

BORE 112 MM (4.4 IN)

STROKE 149 MM (5.9 IN)

(3)

(4)

(5)

(6)

AIR

INLET

EXHAUST

OUTLET

EXHAUST

MANIFOLD

EXHAUST

VALVE

INLET

VALVE

COMPRESSOR

SIDE

TURBINE

SIDE

TURBOCHARGER

INTAKE

HEATER

AFTER COOLER

(7)

AIR

INLET

COMPRESSOR

HOUSING

COMPRESSOR

WHEEL

BEARING

OIL

OUTLET

PORT

TURBINE

HOUSING

BEARING

_TURBINE

WHEEL

EXHAUST

OUTLET

EXHAUST INLET

OIL

INLET

PORT

TURBOCHARGER

(8)

(9)

PUSH ROD

LIFTER

ROCKER ARM

BRIDGE

VALVE

SPRING

(10)

(11)

OIL FILTER

OIL COOLER

HEUI PUMP

TO

TURBOCHARGER

C-9 LUBRICATION SYSTEM

(12)

(13)

CYLINDER

HEAD

CYLINDER

BLOCK

OIL

COOLER

WATER

PUMP

RADIATOR

BYPASS

HOSE

EXPANSION TANK

WATER TEMPERATURE

REGULATOR HOUSING

COOLING SYSTEM

(14)

(15)

OIL GALLERY

MAIN

BEARINGS

(7)

ROD BEARINGS (6)

1

2

3

4

5

6

7

1

2

3

4

5

6

(16)

CRANKSHAFT

_RING

RUBBER RING

HUB

ALIGNMENT

(17)

CRANKSHAFT

WEIGHT

CASE

(18)

C-9 HEUI

SYSTEM POWER SUPPLIES

• ECM

• Injectors and Compression Brake

• Pump Control Valve

• Analog Sensors

• Digital Sensors

• Air Intake Heater

(19)

J2 J1 6 DRIVERS 3 RETURNS ENGINE RETARDER SOLENOIDS ECM TIMING CALIBRATION CONNECTOR GROUND BOLT 20 AMP BREAKER MAIN POWER

RELAY KEY START

SWITCH 24 V 20 AMP FUSE

CRANK WITHOUT INJECT PLUG

(20)

48

52

53

70 ECM (C-9)

24 VOLTS DC

(+)

(-)

ENGINE BLOCK

GROUND BOLT

15 AMP

CIRCUIT BREAKER

BATTERY

R

C

S

B

ST

OFF

ON

KEY SWITCH

P1 J1

(-) BATTERY

61

63

65 (+) 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

DISCONNECT

SWITCH

(21)

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

(22)

2 1 ECM 20 36 44 21 37 45 28 38 46 29 39 47 65 54 67 66 55 68

BRAKE RETURN CYL 1 INJECTOR/BRAKE CYL 1 INJECTOR RETURN CYL 1 BRAKE RETURN CYL 2 INJECTOR/BRAKE CYL 2 INJECTOR RETURN CYL 2 BRAKE RETURN CYL 3 INJECTOR/BRAKE CYL 3 INJECTOR RETURN CYL 3 BRAKE RETURN CYL 4 INJECTOR/BRAKE CYL 4 INJECTOR RETURN CYL 4 BRAKE RETURN CYL 5 INJECTOR/BRAKE CYL 5 INJECTOR RETURN CYL 5 BRAKE RETURN CYL 6 INJECTOR/BRAKE CYL 6 INJECTOR RETURN CYL 6 BRAKE SOLENOID CYL. 6 12 1 18 11 2 17 10 3 16 9 4 15 8 5 14 7 6 13 1 2 2 1 1 2 2 1 1 2 1 2 2 1 1 2 2 1 1 2 P300 J300 P2 J2 2 1 INJECTOR SOLENOID CYL. 6 J306 P306 BRAKE SOLENOID CYL. 5 INJECTOR SOLENOID CYL. 5 J305 P305 BRAKE SOLENOID CYL. 4 INJECTOR SOLENOID CYL. 4 J304 P304 BRAKE SOLENOID CYL. 3 INJECTOR SOLENOID CYL. 3 J303 P303 BRAKE SOLENOID CYL. 2 INJECTOR SOLENOID CYL. 2 J302 P302 BRAKE SOLENOID CYL. 1 INJECTOR SOLENOID CYL. 1 J301 P301

INJECTOR AND COMPRESSION BRAKE

SOLENOID CIRCUITS

(23)

+ CONTROL VALVE

- CONTROL VALVE

61

62 P2 J2

A

B

J500 P500

PUMP CONTROL

VALVE

SUPPLY

RETURN

ECM (C-9 HEUI)

PUMP CONTROL VALVE

POWER SUPPLY

(24)

C

B

A

ENGINE OIL PRESSURE SIGNAL

ANALOG SENSOR RETURN 3

ANALOG SENSOR POWER (+5V) 3

J201/P201

24

42

41 ENGINE OIL PRESSURE SIGNAL

ANALOG SENSOR RETURN 3

ANALOG SENSOR POWER (+5V) 3

C

B

A

FUEL PRESSURE SIGNAL

ANALOG SENSOR RETURN 1

ANALOG SENSOR POWER (+5V) 1

J209/P209

18 FUEL PRESSURE SIGNAL

C

B

A

ATMOSPHERIC PRESSURE SIGNAL

ANALOG SENSOR RETURN 1

ANALOG SENSOR POWER (+5V) 1

J203/P203

14

3

2 C

B

A

HYDRAULIC OIL PRESSURE SIGNAL

ANALOG SENSOR RETURN 1

ANALOG SENSOR POWER (+5V) 1

J204/P204

40

27 TURBO OUTLET PRESSURE SIGNAL

HYDRAULIC OIL PRESSURE SIGNAL

C

B

A

TURBO OUTLET PRESSURE SIGNAL

ANALOG SENSOR RETURN 3

ANALOG SENSOR POWER (+5V) 3

J200/P200

ATMOSPHERIC PRESSURE SIGNAL

ANALOG SENSOR RETURN 1

ANALOG SENSOR POWER (+5V) 1

ECM

P2 J2

ANALOG SENSOR

POWER SUPPLY CIRCUIT

(25)

ECM (C-9 HEUI)

+ V DIGITAL SUPPLY

- V DIGITAL RETURN

4

5 DIGITAL SENSOR

POWER SUPPLY CIRCUIT

P1 J1

A

B

C

J405 P405

A

B

C

+V DIGITAL

DIGITAL RETURN

SIGNAL

FAN

SPEED SENSOR

THROTTLE

POSITION SENSOR

+V DIGITAL

DIGITAL RETURN

SIGNAL

8 ±

0.5 VOLTS

(26)

24V

1

2 B

A

AIR INTAKE

HEATER RELAY

AIR INTAKE

HEATER LAMP

J501 P501

J648

P648

850-BU

1 AIR INTAKE

HEATER RELAY

ECM

AIR INTAKE HEATER CIRCUIT

AIR INTAKE

HEATER

(27)

A

B

C

D

E

F

G

70

65

8

9

34

50 BAT + (SWITCHED)

BAT

-CAT DATA LINK +

CAT DATA LINK

CAN DATA LINK

-CAN DATA LINK +

SERVICE TOOL

CONNECTOR

J63

_{P1 J1}

ENGINE ECM

8

7 CAT DATA LINK +

CAT DATA LINK

-8

7 CAT DATA LINK +

CAT DATA LINK

-TRANSMISSION ECM

CATERPILLAR

MONITORING SYSTEM

(28)

ELECTRONIC CONTROL

SYSTEM

(29)

(30)

(31)

HEUI INJECTOR TESTING

METHODS

• Injector Solenoid Test

• Manual Cylinder Cutout

(32)

ENGINE SPEED

FUEL QUANTITY

FUEL RPM

SELECT

TIMING

CONVERT

DESIRED

TIMING

HYDRAULIC OIL

TEMPERATURE

TIMING CONTROL

DEGREES BTDC

_DESIRED

TIMING

BTDC

TIMING

FUEL INJECTION

TIMING WAVE FORM

(33)

TORQUE

MAPS

AFRC

MAPS

TURBO OUTLET AND

ATMOSPHERIC

PRESSURE SENSORS

ENGINE

CONTROL

LOGIC

THROTTLE

SHUTDOWNS

ENGINE RPM

TDC

6

5

4

3

2

1 SIGNALS

TO FUEL

INJECTORS

FUEL

INJECTION

CONTROL

SPEED/TIMING

SIGNAL

ENGINE RPM

SPEED/TIMING

SENSORS

TIMING

WHEEL

ENGINE RPM

ECM

HYDRAULIC OIL

TEMPERATURE AND

PRESSURE SENSORS

C-9

ELECTRONIC GOVERNOR

ELECTRONIC

GOVERNOR

TO PUMP

CONTROL

VALVE

(34)

59

58

1

2 J402/P402

LOWER (CRANKING)

SPEED/TIMING

SENSOR

J2/P1

1

2 UPPER (HIGH SPEED)

SPEED/TIMING

SENSOR

J401/P401

49

48

1

2

22

23 ECM

- UPPER S/T SENSOR

+ UPPER S/T SENSOR

- LOWER S/T/ SENSOR

+ LOWER S/T SENSOR

+ TIMING CAL PROBE

- TIMING CAL PROBE

(35)

(36)

(37)

CAMSHAFT IDLER GEAR CRANKSHAFT GEAR LOWER SPEED/TIMING SENSOR B (600 TO 1800 OHMS) SENSOR A MEASURED TDC NO.1 SENSOR B MEASURED TDC NO.1 UPPER SPEED/TIMING SENSOR A (75 TO 230 OHMS) GEAR ROTATION SENSOR SIGNALS

UPPER SENSOR A TIMING

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

90° 60° 45° 30° 0° -30° -60° -90° SENSOR B TDC NO.1 SENSOR A TDC NO.1 SENSOR B TDC NO.5 SENSOR A TDC NO.5 15° CRANK 30° CRANK 45° CRANK

SPEED/TIMING SENSING

DUAL PASSIVE SENSORS

45° CRANK

UPPER SENSOR HIGH SPEED LOWER SENSOR

LOW SPEED GEAR TRAIN SHOWN

(38)

(39)

(40)

TIMING CALIBRATION PROBE

POSITIONED 85 CRANKSHAFT

DEG. AFTER TDC

AIR GAP

1 mm (.040 in)

TIMING CALIBRATION

SLOT

ENGINE BLOCK

(SHOWN FROM REAR)

DIRECTION OF

ROTATION

MACHINED FACE

CRANKSHAFT

COUNTERWEIGHT

C-9 TIMING CALIBRATION

PROBE INSTALLATION

TDC POSITION

(41)

REFERENCE EDGE TO TDC DISTANCE

REFERENCE

EDGE

ASSUMED

CYL. NO. 1 TDC

_{CYL. NO. 1 TDC}

ACTUAL

TIMING REFERENCE

OFFSET

(MAXIMUM RANGE

±

3 DEGREES)

TIMING CALIBRATION

SENSOR SIGNAL

TIMING

WHEEL

C-9 TIMING CALIBRATION

-3

°

+3

°

25 ENGINE DEGREES

(42)

TIMING CALIBRATION

PROBE

TIMING CALIBRATION

CONNECTOR

59

58

1

2 J402/P402

LOWER (CRANKING)

SPEED/TIMING

SENSOR

J2/P1

1

2 UPPER (HIGH SPEED)

SPEED/TIMING

SENSOR

J401/P401

49

48

1

2

22

23 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

(43)

(44)

(45)

(46)

(47)

ELECTRONIC SENSORS

AND

(48)

J2

J1

6 COMPRESSION

BRAKE SOLENOIDS

ECM

6 INJECTOR SOLENOIDS

(49)

J2

J1

6 COMPRESSION

BRAKE SOLENOIDS

ECM

6 INJECTOR SOLENOIDS

TIMING CALIBRATION

CONNECTOR

(50)

ENGINE SPEED/TIMING

SENSORS

TIMING CALIBRATION CONNECTOR

6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION

BRAKE SOLENOIDS

(51)

(52)

L u b r i c a t i o n o i l p r e s s u r e

T u r b o c h a r g e r o u t l e t p r e s s u r e

A t m o s p h e r i c p r e s s u r e

C o o l a n t t e m p e r a t u r e

H y d r a u l i c o i l t e m p e r a t u r e

A i r i n t a k e t e m p e r a t u r e

H y d r a u l i c o i l p r e s s u r e

ANALOG SENSORS

(53)

COOLANT TEMP. SENSOR

ENGINE SPEED/TIMING

SENSORS

TIMING CALIBRATION CONNECTOR

6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION

BRAKE SOLENOIDS

(54)

COOLANT TEMP. SENSOR

ENGINE SPEED/TIMING

SENSORS

TIMING CALIBRATION CONNECTOR

6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION

BRAKE SOLENOIDS

ECM

(55)

COOLANT TEMP. SENSOR

ENGINE SPEED/TIMING

SENSORS

TIMING CALIBRATION CONNECTOR

6 INJECTOR SOLENOIDS

J2

J1

6 COMPRESSION

BRAKE SOLENOIDS

ECM

AIR INTAKE TEMP. SENSOR

(56)

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 MAP

ACCORDING TO ATMOSPHERIC PRESSURE

ATMOSPHERIC PRESSURE IN kPa

PERCENT OF FULL LOAD POWER

(57)

COOLANT TEMP. SENSOR ENGINE SPEED/TIMING

SENSORS

TIMING CALIBRATION CONNECTOR 6 INJECTOR SOLENOIDS

J2 J1

6 COMPRESSION BRAKE SOLENOIDS

ECM

AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR (BOOST)

(58)

COOLANT TEMP. SENSOR ENGINE SPEED/TIMING

SENSORS

TIMING CALIBRATION CONNECTOR 6 INJECTOR SOLENOIDS

J2 J1

6 COMPRESSION BRAKE SOLENOIDS

ECM

AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR TURBO INLET PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR

(59)

OIL PRESSURE IN kPa

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

ENGINE RPM

OIL PRESSURE MAP

OIL 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 PRESSURE IN PSI

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

500 400

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

(60)

COOLANT TEMP. SENSOR TIMING CALIBRATION CONNECTOR 6 INJECTOR SOLENOIDS J2 J1 6 COMPRESSION BRAKE 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/TIMING

(61)

COOLANT TEMP. SENSOR ENGINE SPEED/TIMING SENSORS TIMING CALIBRATION CONNECTOR 6 INJECTOR SOLENOIDS J2 J1 6 COMPRESSION BRAKE SOLENOIDS ECM

AIR INTAKE TEMP. SENSOR

ATMOSPHERIC PRESSURE SENSOR

TURBO INLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

(62)

COOLANT TEMP. SENSOR ENGINE SPEED/TIMING SENSORS TIMING CALIBRATION CONNECTOR 6 INJECTOR SOLENOIDS J2 J1 6 COMPRESSION BRAKE SOLENOIDS ECM

AIR INTAKE TEMP. SENSOR

ATMOSPHERIC PRESSURE SENSOR

TURBO INLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

(63)

• Throttle Position Sensor

DIGITAL SENSORS AND CIRCUITS

(64)

J2

J1

ECM

MAIN

POWER

RELAY

KEY

SWITCH

GROUND

BOLT

20 AMP

BREAKER

24 V

DISCONNECT SWITCH

20 AMP FUSE

(65)

90%

ON

OFF

ON

OFF

ON

OFF

10%

50%

DUTY

CYCLE

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

1 CYCLE

= 90%

DUTY

CYCLE

= 50%

DUTY

CYCLE

= 10%

(66)

GND. LEVEL SHUTDOWN (NO)

GND. LEVEL SHUTDOWN (NC)

DIGITAL RETURN

2 P1 J1

GROUND LEVEL

SHUTDOWN SWITCH

8 2 9

ECM

2

1

3

(67)

USER DEFINED SHUTDOWN

59 P1 J1

USER SHUTDOWN

DEVICE

5 DIGITAL RETURN

ECM

(68)

24V

1

2 B

A

AIR INTAKE

HEATER RELAY

AIR INTAKE

HEATER LAMP

J501 P501

J648

P648

850-BU

1 AIR INTAKE

HEATER RELAY

ECM

AIR INTAKE HEATER CIRCUIT

AIR INTAKE

HEATER

(69)

CAT DATA LINK

J2 J1 CAT ELECTRONIC TECHNICIAN

ENGINE

ELECTRONIC CONTROL

MODULE (ECM)

LAPTOP

COMPUTER

SERVICE

TOOL

CONNECTOR

160-0141

SERIAL CABLE

(25 FT.)

160-0133

UNIVERSAL

DATA LINK

CABLE (2 FT.)

COMMUNICATION

ADAPTER II

171-4400 (GP)

PC SERIAL PORT

(COMM PORT)

CATERPILLAR MONITORING SYSTEM

DISPLAY UNIT

TRANSMISSION

ELECTRONIC CONTROL

MODULE

R 0 5 10 15 20 25 30 P X100 24 V MPH km/h 44 AUT

(70)

70

65

42

8

9

34

50 BAT + (SWITCHED)

BAT

-SHIELD

CAT DATA LINK +

CAT DATA LINK

CAN DATA LINK

-CAN DATA LINK +

P1 J1

ENGINE ECM

A

B

C

D

E

F

G

SERVICE TOOL

CONNECTOR

J63

8

7 CAT DATA LINK +

CAT DATA LINK

-8

7 CAT DATA LINK +

CAT DATA LINK

-TRANSMISSION ECM

CATERPILLAR

MONITORING SYSTEM

(71)