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CYLINDER AND VALVE LOCATION INLET VALVES
6
EXHAUST VALVES
5
FIRING ORDER 1 5 3 6 2 4
4
BORE 112 MM (4.4 IN) STROKE 149 MM (5.9 IN)
3
2
1
AIR INTAKE AND EXHAUST SYSTEM
EXHAUST MANIFOLD
EXHAUST VALVE
INTAKE HEATER
INLET VALVE
AIR TO AIR AFTERCOOLER
AIR INLET
EXHAUST OUTLET TURBOCHARGER
COMPRESSOR TURBINE SIDE SIDE
TURBOCHARGER OIL BEARING TURBINE TURBINE INLET HOUSING WHEEL PORT
COMPRESSOR HOUSING
EXHAUST OUTLET
AIR INLET
COMPRESSOR WHEEL
BEARING
OIL OUTLET 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
BY HOSE
CYLINDER BLOCK
OIL COOLER
WATER PUMP
RADIATOR
CRANKSHAFT OIL FLOW OIL GALLERY
MAIN BEARINGS (7) 7
5
6 6
5
3
4 4
3
ROD BEARINGS (6)
2 2
1 1
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 BOLT
6 DRIVERS
DISCONNECT SWITCH 3 RETURNS ENGINE RETARDER SOLENOIDS TIMING CALIBRATION CONNECTOR
24 V
20 AMP FUSE 20 AMP BREAKER MAIN POWER RELAY
KEY START SWITCH
CRANK WITHOUT INJECT PLUG
ECM POWER SUPPLY CIRCUIT BATTERY
ENGINE BLOCK GROUND BOLT (-)
24 VOLTS DC (+)
20 A DISCONNECT SWITCH
FUSE
P1 J1
61 63 65 48 52 53 70
(-) (-) (-) (+) (+) (+) (+)
ECM (C-9) BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY SWITCHED POWER
WIRE FUNCTION COLOR CODE (+) BATTERY SUPPLY WIRES INPUT SIGNAL WIRES TO ECM
R
OUTPUT SIGNAL WIRES FROM ECM SENSOR SUPPLY VOLTAGE SIGNAL PLUS SIGNAL MINUS (-) BATTERY / SENSOR RETURN
15 AMP CIRCUIT BREAKER
C OFF S ON B ST KEY SWITCH
ECM CONNECTOR (P1)
1
2
3
4
5
6
8
9
10
11 12 13
13
1
23
14
31
24
39
32
47
40
40
47
57
48
48
57
70
58
14
31
24 36
58 59 60 61 62
ECM SIDE
23
>PEI<
63
65 66 67 68 69 70
HARNESS SIDE
INJECTOR AND COMPRESSION BRAKE SOLENOID CIRCUITS 2 1 BRAKE SOLENOID CYL. 1
J301 P301 1 2
2 1 BRAKE SOLENOID CYL. 2 J302 P302 1 2
2 1 BRAKE SOLENOID CYL. 3 J303 P303 1 2
2 1 BRAKE SOLENOID CYL. 4 J304 P304 1 2
INJECTOR SOLENOID CYL. 1
2 1 BRAKE SOLENOID CYL. 5 J305 P305 1 2
INJECTOR SOLENOID CYL. 2
2 1 BRAKE SOLENOID CYL. 6 J306 P306 1 2
INJECTOR SOLENOID CYL. 3 INJECTOR SOLENOID CYL. 4
INJECTOR SOLENOID CYL. 5
INJECTOR SOLENOID CYL. 6
12 1 18 11 2 17 10 3 16 9 4 15 8 5 14 7 6 13 P300 J300
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
20 36 44 21 37 45 28 38 46 29 39 47 65 54 67 66 55 68 P2
J2
ECM
PUMP CONTROL VALVE POWER SUPPLY PUMP CONTROL VALVE SUPPLY RETURN
J500 P500 A B
P2 J2 61 62
ECM (C-9 HEUI) + CONTROL VALVE - CONTROL VALVE
TURBO OUTLET PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3
J200/P200 C B A
HYDRAULIC OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
J204/P204 C B A
ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
J203/P203 C B A
FUEL PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
J209/P209 C B A
ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3
J201/P201 C B A
ANALOG SENSOR POWER SUPPLY CIRCUIT 5 ± 0.5 VOLTS P2 J2
ECM
40 27
TURBO OUTLET PRESSURE SIGNAL HYDRAULIC OIL PRESSURE SIGNAL
14 3 2
ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
18
FUEL PRESSURE SIGNAL
24 42 41
ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3
THROTTLE POSITION SENSOR
J405 P405
+V DIGITAL DIGITAL RETURN SIGNAL
A B C
4 5
ECM (C-9 HEUI) + V DIGITAL SUPPLY - V DIGITAL RETURN
DIGITAL SENSOR POWER SUPPLY CIRCUIT
FAN SPEED SENSOR +V DIGITAL DIGITAL RETURN SIGNAL
P1 J1
A B C
8 ± 0.5 VOLTS
AIR INTAKE HEATER CIRCUIT AIR INTAKE HEATER LAMP
24V
B A
J648 P648
AIR INTAKE HEATER
AIR INTAKE HEATER RELAY
J501/P501 1 2
850-BU
ECM J2/P2 AIR INTAKE 12 HEATER RELAY
TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT CATERPILLAR MONITORING SYSTEM
TRANSMISSION ECM R OFF C ON S ST B
KEY SWITCH
CAT DATA LINK + CAT DATA LINK -
8 7
J63
A B C D E F G
SERVICE TOOL CONNECTOR
DATA LINKS
8 7
CAT DATA LINK + CAT DATA LINK -
ENGINE ECM
P1 J1 70 65
BAT + (SWITCHED) BAT -
8 9 34 50
CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +
ELECTRONIC CONTROL SYSTEM
HEUI INJECTOR TESTING METHODS • Injector Solenoid Test • Manual Cylinder Cutout • Automatic Cylinder Cutout Test
C-9 HEUI CONTROL LOGIC TIMING CONTROL ENGINE SPEED FUEL QUANTITY HYDRAULIC OIL TEMPERATURE
TIMING
DEGREES BTDC
FUEL RPM SELECT TIMING
DESIRED TIMING BTDC
CONVERT DESIRED TIMING
FUEL INJECTION TIMING WAVE FORM
C-9 ELECTRONIC GOVERNOR
HYDRAULIC OIL TEMPERATURE AND PRESSURE SENSORS
SHUTDOWNS
ECM TO PUMP CONTROL VALVE
ELECTRONIC GOVERNOR
6 5 SIGNALS 4 TO FUEL 3 INJECTORS 2 1 SPEED/TIMING SIGNAL
FUEL INJECTION CONTROL
ENGINE RPM
TORQUE MAPS
ENGINE CONTROL LOGIC
THROTTLE
TDC ENGINE RPM
ENGINE RPM SPEED/TIMING SENSORS
TIMING WHEEL
AFRC MAPS
TURBO OUTLET AND ATMOSPHERIC PRESSURE SENSORS
C-9 SPEED/TIMING SENSORS UPPER (HIGH SPEED) SPEED/TIMING SENSOR
J401/P401 1 2
LOWER (CRANKING) SPEED/TIMING SENSOR
J2/P2
ECM
49 48
- UPPER S/T SENSOR + UPPER S/T SENSOR
1 2
59 58
- LOWER S/T/ SENSOR + LOWER S/T SENSOR
1 2
22 23
+ TIMING CAL PROBE - TIMING CAL PROBE
J402/P402
SPEED/TIMING SENSING DUAL IVE SENSORS
GEAR TRAIN SHOWN FROM FRONT OF ENGINE
45° CRANK UPPER SPEED/TIMING SENSOR A (75 TO 230 OHMS)
LOWER SPEED/TIMING SENSOR B (600 TO 1800 OHMS)
SENSOR A MEASURED TDC NO.1
CAMSHAFT IDLER GEAR
45° CRANK
SENSOR B MEASURED TDC NO.1
LOWER SENSOR LOW SPEED
UPPER SENSOR HIGH SPEED 30° CRANK
15° CRANK CRANKSHAFT GEAR
GEAR ROTATION SENSOR B TDC NO.1
SENSOR A TDC NO.1
SENSOR B TDC NO.5
SENSOR A TDC NO.5
SENSOR SIGNALS
UPPER SENSOR A TIMING
-90°
-60°
-30°
0°
30°
45°
LOWER SENSOR B TIMING -70°
-45°
-15° -0°
15°
45°
75°
90° 105°
60°
90°
C-9 TIMING CALIBRATION PROBE INSTALLATION TDC POSITION CRANKSHAFT COUNTERWEIGHT
MACHINED FACE
DIRECTION OF ROTATION TIMING CALIBRATION PROBE POSITIONED 85 CRANKSHAFT DEG. AFTER TDC TIMING CALIBRATION SLOT
ENGINE BLOCK (SHOWN FROM REAR) AIR GAP 1 mm (.040 in)
C-9 TIMING CALIBRATION TIMING WHEEL
REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE
ASSUMED CYL. NO. 1 TDC
-3° TIMING CALIBRATION SENSOR SIGNAL
25 ENGINE DEGREES
ACTUAL CYL. NO. 1 TDC
+3° TIMING REFERENCE OFFSET (MAXIMUM RANGE ± 3 DEGREES)
C-9 SPEED/TIMING SENSORS CALIBRATION UPPER (HIGH SPEED) SPEED/TIMING SENSOR
J401/P401 1 2
LOWER (CRANKING) SPEED/TIMING SENSOR
J2/P2
ECM
49 48
- UPPER S/T SENSOR + UPPER S/T SENSOR
59 58
- LOWER S/T/ SENSOR + LOWER S/T SENSOR
22 23
+ TIMING CAL PROBE - TIMING CAL PROBE
J402/P402 1 2
TIMING CALIBRATION PROBE
J400/P400 1 2
TIMING CALIBRATION CONNECTOR
ELECTRONIC SENSORS AND SYSTEMS
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
J2
J1
ANALOG SENSORS • Hydraulic oil temperature • Lubrication oil pressure • Air intake temperature • Atmospheric pressure • Hydraulic oil pressure • Turbocharger outlet pressure • Coolant temperature
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR
AIR INTAKE TEMP. SENSOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR
J2
J1
ENGINE POWER DERATING MAP 100%
7,500
98%
8,210
96%
8,920
94%
9,630
92%
10,340
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
ATMOSPHERIC PRESSURE IN kPa
ALTITUDE IN FEET
PERCENT OF FULL LOAD POWER
ACCORDING TO ATMOSPHERIC PRESSURE
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO OUTLET PRESSURE SENSOR (BOOST)
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR
AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO OUTLET PRESSURE SENSOR
ENGINE OIL PRESSURE SENSOR
J2
J1
OIL PRESSURE MAP OIL PRESSURE WARNING AND DERATE TRIP POINTS 190
27.6
180
26.1
175 kPa (25 psi) RESET LINE
170
24.7
160
23.2
150
154 kPa (22 psi) TRIP LINE
20.3
130
18.9
125 kPa (18 psi) RESET LINE
120
17.4
110
16.0
100
14.5
104 kPa (15 psi) TRIP LINE
90
13.1
80
11.6
70
10.2
60
8.7
LOW OIL PRESSURE WARNING
7.3
50
VERY LOW OIL PRESSURE DERATE
40
5.8
30
4.4
20
2.9
10
1.5
0
0
400
500
600
kPa x 0.145 = PSI
700
800
900
1000
1100
1200
1300
ENGINE RPM
1400
1500
1600
1700
1800
1900
2000
2200
OIL PRESSURE IN PSI
OIL PRESSURE IN kPa
140
21.8
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR
FUEL PRESSURE SENSOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR
FUEL PRESSURE SENSOR
HYDRAULIC OIL TEMP. SENSORS
OIL VISCOSITY SELECTION CONNECTOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS 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
J2
J1
DIGITAL SENSORS AND CIRCUITS • Throttle Position Sensor • Fan Speed Sensor
J2
J1
ECM
GROUND BOLT
DISCONNECT SWITCH
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 1 2 3
P1 J1 2 8 29
ECM GND. LEVEL SHUTDOWN (NO) GND. LEVEL SHUTDOWN (NC) DIGITAL RETURN
DEFINED SHUTDOWN CIRCUIT
P1 J1 SHUTDOWN DEVICE
59 5
ECM DEFINED SHUTDOWN DIGITAL RETURN
AIR INTAKE HEATER CIRCUIT AIR INTAKE HEATER LAMP
24V B A
J648 P648
AIR INTAKE HEATER
AIR INTAKE HEATER RELAY
J501/P501 1 2
850-BU
ECM J2/P2 AIR INTAKE 12 HEATER RELAY
CAT DATA LINK UNIVERSAL DATA LINK CABLE (2 FT.)
J2
SERIAL CABLE (25 FT.)
J1
ENGINE ELECTRONIC CONTROL MODULE (ECM)
PC SERIAL PORT (COMM PORT)
SERVICE TOOL CONNECTOR
COMMUNICATION ADAPTER II 171-4400 (GP)
CAT ELECTRONIC TECHNICIAN
LAPTOP COMPUTER
P
15
TRANSMISSION ELECTRONIC CONTROL MODULE
10 5
25 X100
R 24 V
AUT
20
0
MPH km/h
30
CATERPILLAR MONITORING SYSTEM DISPLAY UNIT
44
TYPICAL CAT / CAN DATA LINK CIRCUIT CATERPILLAR MONITORING SYSTEM
TRANSMISSION ECM
CAT DATA LINK + CAT DATA LINK -
8 7
J63
A B C D E F G SERVICE TOOL CONNECTOR
DATA LINKS
8 7
P1 J1 70 65 42 8 9 34 50
CAT DATA LINK + CAT DATA LINK -
ENGINE ECM
BAT + (SWITCHED) BAT SHIELD CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +
6
EXHAUST VALVES
5
FIRING ORDER 1 5 3 6 2 4
4
BORE 112 MM (4.4 IN) STROKE 149 MM (5.9 IN)
3
2
1
AIR INTAKE AND EXHAUST SYSTEM
EXHAUST MANIFOLD
EXHAUST VALVE
INTAKE HEATER
INLET VALVE
AIR TO AIR AFTERCOOLER
AIR INLET
EXHAUST OUTLET TURBOCHARGER
COMPRESSOR TURBINE SIDE SIDE
TURBOCHARGER OIL BEARING TURBINE TURBINE INLET HOUSING WHEEL PORT
COMPRESSOR HOUSING
EXHAUST OUTLET
AIR INLET
COMPRESSOR WHEEL
BEARING
OIL OUTLET 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
BY HOSE
CYLINDER BLOCK
OIL COOLER
WATER PUMP
RADIATOR
CRANKSHAFT OIL FLOW OIL GALLERY
MAIN BEARINGS (7) 7
5
6 6
5
3
4 4
3
ROD BEARINGS (6)
2 2
1 1
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 BOLT
6 DRIVERS
DISCONNECT SWITCH 3 RETURNS ENGINE RETARDER SOLENOIDS TIMING CALIBRATION CONNECTOR
24 V
20 AMP FUSE 20 AMP BREAKER MAIN POWER RELAY
KEY START SWITCH
CRANK WITHOUT INJECT PLUG
ECM POWER SUPPLY CIRCUIT BATTERY
ENGINE BLOCK GROUND BOLT (-)
24 VOLTS DC (+)
20 A DISCONNECT SWITCH
FUSE
P1 J1
61 63 65 48 52 53 70
(-) (-) (-) (+) (+) (+) (+)
ECM (C-9) BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY SWITCHED POWER
WIRE FUNCTION COLOR CODE (+) BATTERY SUPPLY WIRES INPUT SIGNAL WIRES TO ECM
R
OUTPUT SIGNAL WIRES FROM ECM SENSOR SUPPLY VOLTAGE SIGNAL PLUS SIGNAL MINUS (-) BATTERY / SENSOR RETURN
15 AMP CIRCUIT BREAKER
C OFF S ON B ST KEY SWITCH
ECM CONNECTOR (P1)
1
2
3
4
5
6
8
9
10
11 12 13
13
1
23
14
31
24
39
32
47
40
40
47
57
48
48
57
70
58
14
31
24 36
58 59 60 61 62
ECM SIDE
23
>PEI<
63
65 66 67 68 69 70
HARNESS SIDE
INJECTOR AND COMPRESSION BRAKE SOLENOID CIRCUITS 2 1 BRAKE SOLENOID CYL. 1
J301 P301 1 2
2 1 BRAKE SOLENOID CYL. 2 J302 P302 1 2
2 1 BRAKE SOLENOID CYL. 3 J303 P303 1 2
2 1 BRAKE SOLENOID CYL. 4 J304 P304 1 2
INJECTOR SOLENOID CYL. 1
2 1 BRAKE SOLENOID CYL. 5 J305 P305 1 2
INJECTOR SOLENOID CYL. 2
2 1 BRAKE SOLENOID CYL. 6 J306 P306 1 2
INJECTOR SOLENOID CYL. 3 INJECTOR SOLENOID CYL. 4
INJECTOR SOLENOID CYL. 5
INJECTOR SOLENOID CYL. 6
12 1 18 11 2 17 10 3 16 9 4 15 8 5 14 7 6 13 P300 J300
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
20 36 44 21 37 45 28 38 46 29 39 47 65 54 67 66 55 68 P2
J2
ECM
PUMP CONTROL VALVE POWER SUPPLY PUMP CONTROL VALVE SUPPLY RETURN
J500 P500 A B
P2 J2 61 62
ECM (C-9 HEUI) + CONTROL VALVE - CONTROL VALVE
TURBO OUTLET PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3
J200/P200 C B A
HYDRAULIC OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
J204/P204 C B A
ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
J203/P203 C B A
FUEL PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
J209/P209 C B A
ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3
J201/P201 C B A
ANALOG SENSOR POWER SUPPLY CIRCUIT 5 ± 0.5 VOLTS P2 J2
ECM
40 27
TURBO OUTLET PRESSURE SIGNAL HYDRAULIC OIL PRESSURE SIGNAL
14 3 2
ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1
18
FUEL PRESSURE SIGNAL
24 42 41
ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3
THROTTLE POSITION SENSOR
J405 P405
+V DIGITAL DIGITAL RETURN SIGNAL
A B C
4 5
ECM (C-9 HEUI) + V DIGITAL SUPPLY - V DIGITAL RETURN
DIGITAL SENSOR POWER SUPPLY CIRCUIT
FAN SPEED SENSOR +V DIGITAL DIGITAL RETURN SIGNAL
P1 J1
A B C
8 ± 0.5 VOLTS
AIR INTAKE HEATER CIRCUIT AIR INTAKE HEATER LAMP
24V
B A
J648 P648
AIR INTAKE HEATER
AIR INTAKE HEATER RELAY
J501/P501 1 2
850-BU
ECM J2/P2 AIR INTAKE 12 HEATER RELAY
TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT CATERPILLAR MONITORING SYSTEM
TRANSMISSION ECM R OFF C ON S ST B
KEY SWITCH
CAT DATA LINK + CAT DATA LINK -
8 7
J63
A B C D E F G
SERVICE TOOL CONNECTOR
DATA LINKS
8 7
CAT DATA LINK + CAT DATA LINK -
ENGINE ECM
P1 J1 70 65
BAT + (SWITCHED) BAT -
8 9 34 50
CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +
ELECTRONIC CONTROL SYSTEM
HEUI INJECTOR TESTING METHODS • Injector Solenoid Test • Manual Cylinder Cutout • Automatic Cylinder Cutout Test
C-9 HEUI CONTROL LOGIC TIMING CONTROL ENGINE SPEED FUEL QUANTITY HYDRAULIC OIL TEMPERATURE
TIMING
DEGREES BTDC
FUEL RPM SELECT TIMING
DESIRED TIMING BTDC
CONVERT DESIRED TIMING
FUEL INJECTION TIMING WAVE FORM
C-9 ELECTRONIC GOVERNOR
HYDRAULIC OIL TEMPERATURE AND PRESSURE SENSORS
SHUTDOWNS
ECM TO PUMP CONTROL VALVE
ELECTRONIC GOVERNOR
6 5 SIGNALS 4 TO FUEL 3 INJECTORS 2 1 SPEED/TIMING SIGNAL
FUEL INJECTION CONTROL
ENGINE RPM
TORQUE MAPS
ENGINE CONTROL LOGIC
THROTTLE
TDC ENGINE RPM
ENGINE RPM SPEED/TIMING SENSORS
TIMING WHEEL
AFRC MAPS
TURBO OUTLET AND ATMOSPHERIC PRESSURE SENSORS
C-9 SPEED/TIMING SENSORS UPPER (HIGH SPEED) SPEED/TIMING SENSOR
J401/P401 1 2
LOWER (CRANKING) SPEED/TIMING SENSOR
J2/P2
ECM
49 48
- UPPER S/T SENSOR + UPPER S/T SENSOR
1 2
59 58
- LOWER S/T/ SENSOR + LOWER S/T SENSOR
1 2
22 23
+ TIMING CAL PROBE - TIMING CAL PROBE
J402/P402
SPEED/TIMING SENSING DUAL IVE SENSORS
GEAR TRAIN SHOWN FROM FRONT OF ENGINE
45° CRANK UPPER SPEED/TIMING SENSOR A (75 TO 230 OHMS)
LOWER SPEED/TIMING SENSOR B (600 TO 1800 OHMS)
SENSOR A MEASURED TDC NO.1
CAMSHAFT IDLER GEAR
45° CRANK
SENSOR B MEASURED TDC NO.1
LOWER SENSOR LOW SPEED
UPPER SENSOR HIGH SPEED 30° CRANK
15° CRANK CRANKSHAFT GEAR
GEAR ROTATION SENSOR B TDC NO.1
SENSOR A TDC NO.1
SENSOR B TDC NO.5
SENSOR A TDC NO.5
SENSOR SIGNALS
UPPER SENSOR A TIMING
-90°
-60°
-30°
0°
30°
45°
LOWER SENSOR B TIMING -70°
-45°
-15° -0°
15°
45°
75°
90° 105°
60°
90°
C-9 TIMING CALIBRATION PROBE INSTALLATION TDC POSITION CRANKSHAFT COUNTERWEIGHT
MACHINED FACE
DIRECTION OF ROTATION TIMING CALIBRATION PROBE POSITIONED 85 CRANKSHAFT DEG. AFTER TDC TIMING CALIBRATION SLOT
ENGINE BLOCK (SHOWN FROM REAR) AIR GAP 1 mm (.040 in)
C-9 TIMING CALIBRATION TIMING WHEEL
REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE
ASSUMED CYL. NO. 1 TDC
-3° TIMING CALIBRATION SENSOR SIGNAL
25 ENGINE DEGREES
ACTUAL CYL. NO. 1 TDC
+3° TIMING REFERENCE OFFSET (MAXIMUM RANGE ± 3 DEGREES)
C-9 SPEED/TIMING SENSORS CALIBRATION UPPER (HIGH SPEED) SPEED/TIMING SENSOR
J401/P401 1 2
LOWER (CRANKING) SPEED/TIMING SENSOR
J2/P2
ECM
49 48
- UPPER S/T SENSOR + UPPER S/T SENSOR
59 58
- LOWER S/T/ SENSOR + LOWER S/T SENSOR
22 23
+ TIMING CAL PROBE - TIMING CAL PROBE
J402/P402 1 2
TIMING CALIBRATION PROBE
J400/P400 1 2
TIMING CALIBRATION CONNECTOR
ELECTRONIC SENSORS AND SYSTEMS
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
J2
J1
ANALOG SENSORS • Hydraulic oil temperature • Lubrication oil pressure • Air intake temperature • Atmospheric pressure • Hydraulic oil pressure • Turbocharger outlet pressure • Coolant temperature
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR
AIR INTAKE TEMP. SENSOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR
J2
J1
ENGINE POWER DERATING MAP 100%
7,500
98%
8,210
96%
8,920
94%
9,630
92%
10,340
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
ATMOSPHERIC PRESSURE IN kPa
ALTITUDE IN FEET
PERCENT OF FULL LOAD POWER
ACCORDING TO ATMOSPHERIC PRESSURE
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO OUTLET PRESSURE SENSOR (BOOST)
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS
TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR
AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR
TURBO OUTLET PRESSURE SENSOR
ENGINE OIL PRESSURE SENSOR
J2
J1
OIL PRESSURE MAP OIL PRESSURE WARNING AND DERATE TRIP POINTS 190
27.6
180
26.1
175 kPa (25 psi) RESET LINE
170
24.7
160
23.2
150
154 kPa (22 psi) TRIP LINE
20.3
130
18.9
125 kPa (18 psi) RESET LINE
120
17.4
110
16.0
100
14.5
104 kPa (15 psi) TRIP LINE
90
13.1
80
11.6
70
10.2
60
8.7
LOW OIL PRESSURE WARNING
7.3
50
VERY LOW OIL PRESSURE DERATE
40
5.8
30
4.4
20
2.9
10
1.5
0
0
400
500
600
kPa x 0.145 = PSI
700
800
900
1000
1100
1200
1300
ENGINE RPM
1400
1500
1600
1700
1800
1900
2000
2200
OIL PRESSURE IN PSI
OIL PRESSURE IN kPa
140
21.8
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS
COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR
ATMOSPHERIC PRESSURE SENSOR TURBO OUTLET PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR
FUEL PRESSURE SENSOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS COOLANT TEMP. SENSOR AIR INTAKE TEMP. SENSOR ATMOSPHERIC PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR
FUEL PRESSURE SENSOR
HYDRAULIC OIL TEMP. SENSORS
OIL VISCOSITY SELECTION CONNECTOR
J2
J1
ECM 6 INJECTOR SOLENOIDS
6 COMPRESSION BRAKE SOLENOIDS TIMING CALIBRATION CONNECTOR
ENGINE SPEED/TIMING SENSORS 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
J2
J1
DIGITAL SENSORS AND CIRCUITS • Throttle Position Sensor • Fan Speed Sensor
J2
J1
ECM
GROUND BOLT
DISCONNECT SWITCH
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 1 2 3
P1 J1 2 8 29
ECM GND. LEVEL SHUTDOWN (NO) GND. LEVEL SHUTDOWN (NC) DIGITAL RETURN
DEFINED SHUTDOWN CIRCUIT
P1 J1 SHUTDOWN DEVICE
59 5
ECM DEFINED SHUTDOWN DIGITAL RETURN
AIR INTAKE HEATER CIRCUIT AIR INTAKE HEATER LAMP
24V B A
J648 P648
AIR INTAKE HEATER
AIR INTAKE HEATER RELAY
J501/P501 1 2
850-BU
ECM J2/P2 AIR INTAKE 12 HEATER RELAY
CAT DATA LINK UNIVERSAL DATA LINK CABLE (2 FT.)
J2
SERIAL CABLE (25 FT.)
J1
ENGINE ELECTRONIC CONTROL MODULE (ECM)
PC SERIAL PORT (COMM PORT)
SERVICE TOOL CONNECTOR
COMMUNICATION ADAPTER II 171-4400 (GP)
CAT ELECTRONIC TECHNICIAN
LAPTOP COMPUTER
P
15
TRANSMISSION ELECTRONIC CONTROL MODULE
10 5
25 X100
R 24 V
AUT
20
0
MPH km/h
30
CATERPILLAR MONITORING SYSTEM DISPLAY UNIT
44
TYPICAL CAT / CAN DATA LINK CIRCUIT CATERPILLAR MONITORING SYSTEM
TRANSMISSION ECM
CAT DATA LINK + CAT DATA LINK -
8 7
J63
A B C D E F G SERVICE TOOL CONNECTOR
DATA LINKS
8 7
P1 J1 70 65 42 8 9 34 50
CAT DATA LINK + CAT DATA LINK -
ENGINE ECM
BAT + (SWITCHED) BAT SHIELD CAT DATA LINK + CAT DATA LINK CAN DATA LINK CAN DATA LINK +
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