Service Training SERH4050

May 2003

C-9 ENGINE
SYSTEMS AND CONTROLS
C-9 ENGINE
SYSTEMS AND CONTROLS
VISUALS AND SCRIPT
AUDIENCE
Level II--Service personnel who understand the principles of engine systems operation, diagnostic
equipment, and procedures for testing and adjusting.

CONTENT
This presentation is designed to prepare a service technician to identify the components, explain their
function, and service the C-9 Engine in all machine and industrial applications.

OBJECTIVES
After learning the information in this presentation, the serviceman will be able to:
1. Locate and identify the major components in the C-9 engine systems.
2. Explain the functions of the major components in the C-9 engine systems.
3. Trace the flow of fuel and oil through the fuel system.
4. Trace the flow of current through the engine electrical system.

PREREQUISITES
Interactive Video Course "Fundamentals of Electrical Systems" (CD ROM) TEMV9002
Service Technician Workbench Tutorial (CD ROM included with STW software) NEHS0812
Caterpillar Machine Electronics Course (Five Modules) SEGV3001 - SEGV3005
Caterpillar HEUI HI300B Fuel System (CD ROM) RENR1392

Prior training in systems operation and testing and adjusting procedures for electronic engines should be
completed before participating in this training session. Additionally, the participants should have PC
skills including training in the current Windows™ operating system and the most current Service
Technician Workbench/Electronic Technician (STW/ET) software.

Additional material is also provided with this package. Photos of the HEUI pump are provided where
cutaway training aids are not available.
Four serviceman's handouts are provided with this STMG. However, as this publication is available
electronically, it can be printed in color and used selectively or totally, in the class as a handout. This
feature will enable the student to follow the presentation and make notes in the book.

The C9 Truck Engine with ACERT Technology is not included in this training manual. However, these
two sources can be used but are in a separate publication

This engine is defined by the designation "C9" (with no dash)..

Estimated Time: 8 Hours

Visuals: 72 Electronic Visuals
Date: 05/2003

© 2003 Caterpillar Inc.

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SUPPLEMENTARY TRAINING MATERIAL

Brochure "Service Technician Workbench" NELG5028
Brochure "Caterpillar Electronic Technician" NEDG6015

Service Technician Workbench Tutorial (Included with STW software) NEHS0812

Caterpillar HEUI Fuel System (Interactive CD ROM) RENR1392

RECOMMENDED C-9 ENGINE TOOLING

Software and Manuals
Caterpillar Service Tool Software/Getting Started Guide - Service Technician Workbench NEHS0796
or Caterpillar Service Tool Software/Getting Started - Caterpillar Electronic Technician JEBD3003
Caterpillar Service Tool Software/Users Manual- Communication Adapter II 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 (See Student Handout # 4) 96-0055
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

REFERENCES
Systems Operation Testing and Adjusting "C-9 Industrial Engines" SENR9598-02
Systems Operation Testing and Adjusting "C-9 Engine for Caterpillar Built Machines" SENR9501
Troubleshooting Manual "C-9 Engine for Caterpillar Built Machines" D6R Tractor SENR9503
Disassembly and Assembly "C-9 Engines for Caterpillar Built Machines" SENR9502
Specifications Manual "C-9 Engines for Caterpillar Built Machines" SENR9500
Diagnostic Cables and Harnesses NEHS0822
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TABLE OF CONTENTS

INTRODUCTION TO SYSTEMS OPERATION

Introduction ......................................................................................................................7
Lab Exercise ...................................................................................................................25
Engine Lab Component List ...........................................................................................26

SYSTEM POWER SUPPLIES

Introduction ....................................................................................................................27
ECM Power Supply .......................................................................................................28
Injector and Compression Brake Power Supply ............................................................32
Hydraulic Pump Control Valve Power Supply ...............................................................33
Analog Sensor Power Supply ........................................................................................34
Digital Sensor Power Supply .........................................................................................35
Air Intake Heater Power Supply .....................................................................................36
Service Tool Power Supply.............................................................................................37
Lab Exercise ...................................................................................................................38

ELECTRONIC CONTROL SYSTEM

Introduction ....................................................................................................................41
Fuel Injection .................................................................................................................44
Fuel Injection Control System .......................................................................................46

SYSTEM CALIBRATIONS
Introduction ....................................................................................................................53
Speed/Timing Sensor Calibration ..................................................................................53
Injector Calibration ........................................................................................................58
Pressure Sensor Calibration ...........................................................................................60
Oil Grade Detection .......................................................................................................61
Engine Warnings and Derates .........................................................................................63
Lab Exercise ...................................................................................................................64

ELECTRONIC SENSORS AND SYSTEMS

Introduction ....................................................................................................................67
Injector and Compression Brake Systems ......................................................................68
Speed/Timing Sensors ....................................................................................................69
Analog Sensors and Circuits ..........................................................................................72
Digital Sensors and Circuits ...........................................................................................86
Engine Shutdown Systems .............................................................................................89
Cold Starting Aids .........................................................................................................90
Data Link Circuits ..........................................................................................................94
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TABLE OF CONTENTS

CONCLUSION ....................................................................................................................97
Lab Exercise ...................................................................................................................98

VISUAL LIST .....................................................................................................................99

STUDENT HANDOUTS ..................................................................................................100

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INTRODUCTION TO SYSTEMS OPERATION

• Introduction Introduction

This presentation describes the C-9 Engine Structure, Air Intake and
Exhaust, Cooling, Lubrication, Electrical and Fuel Systems.

Each portion of the training manual is followed by a lab exercise to

reinforce the location and function of each component.

The training manual is laid out as follows:

• Manual contents Introduction to Systems Operation
System Power Supplies
Electronic Control System
System Calibrations
Electronic Sensors and Systems

• Introduction INSTRUCTOR NOTE: The Systems Operation portion of the Systems

- Use Systems Operation Testing and Adjusting manual for C-9 Industrial Engines
Operation manual (SENR9598-02) can be used to supplement the Visual/Text information.
for reference
A separate publication, Caterpillar C-9 Hydraulic Electronic Unit
Injection (HEUI) Fuel system CD ROM (RENR1392) should also be used
to describe the HEUI fuel system in detail.
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CYLINDER AND VALVE LOCATION

INLET
VALVES FIRING ORDER 1 5 3 6 2 4

6 5 4 3 2 1

EXHAUST BORE 112 MM (4.4 IN)

VALVES STROKE 149 MM (5.9 IN)

• Cylinder and valve The C-9 engine has an in-line six cylinder arrangement. The engine has a
location bore of 112 mm (4.4 in) and a stroke of 149 mm (5.9 in). The engine
• 8.8 liters displacement displacement is 8.8 liters.

• Inlet and exhaust Note the arrangement of the inlet and exhaust valves for identification
valve arrangement purposes.

• Compression ratio The compression ratio is typically 16.2/1

• Horse power The Horse Power may vary from 250 to 525 depending on the
application.
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• Major components This view of an industrial engine, shows some of the major components
of the engine.

The major fuel system and electronic components are mounted on the left
hand side of the engine.

• ECM Note the ECM on the lower right hand side of the picture.

The Systems Operation portion of the Systems Operation Testing and

Adjusting manual for C-9 Industrial Engines (SENR9598-02) can be used
to locate the various components. Otherwise the appropriate Service
Manual for the application should be used.
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• HEUI system This visual is taken from the Caterpillar HEUI HI300B Fuel System CD
schematic RENR1392. This CD will supply all the information on the HEUI fuel
system, electronics and related diagnostics.

• Similar to other HEUI This HEUI system is very similar to the 3408E, 3412E and 3126 HEUI
systems systems. There are a number of features which differ from other engines.

• Some system The hydraulic pump is a completely new design.

differences
- New HEUI hydraulic There are no jumper tubes on the injectors. Oil under pressure is fed
pump
directly from the cylinder head to the injectors.
- No jumper tubes
- Two hydraulic oil There are two Hydraulic Oil Temperature Sensors installed on the engine.
temperature sensors
- Water in fuel and Optional water in fuel and fuel pressure sensors may be installed in the
fuel pressure
sensors available fuel supply system.

See also Student Handout No. 1 for a fuel supply system diagram.
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• HEUI system This view shows a cutaway of the HEUI pump.

hydraulic pump
The hydraulic pump is a high pressure, variable delivery piston pump.
This pump provides the hydraulic power to actuate the injectors.

• Transfer pump The fuel system transfer pump is mounted on the rear of the hydraulic
mounted on rear of pump and will deliver 400 - 434 kPa (58 - 63 psi) at normal operating load
HEUI pump and speed*

This pump is fully described in the CD RENR1392 (described on the

previous page).

*Consult the Systems Operation Testing and Adjusting Manual for the
Testing Specifications.
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• Cross flow cylinder The C-9 engine has a cross flow cylinder head. This feature allows for
head improved emissions and fuel consumption by improving the combustion
- Improves emissions
airflow through the engine.
and fuel
consumption
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AIR INTAKE AND EXHAUST SYSTEM

EXHAUST
MANIFOLD INTAKE AIR TO AIR
HEATER AFTERCOOLER

INLET AIR EXHAUST

EXHAUST OUTLET
VALVE VALVE INLET
TURBOCHARGER
COMPRESSOR TURBINE
SIDE SIDE

• Air intake and exhaust The air to air aftercooler is used in most applications, the exception is the
system schematic marine engine. By cooling the precharge air, this component increases
the mass flow of air through the engine, thus allowing more fuel and more
horsepower.
• Air intake heater
The air intake heater is used to aid starting and reduce white smoke in
cold conditions.

In most applications, the air intake heater has replaced the ether aid. In
extreme cold (Arctic) conditions, it is possible to have the ether aid and
the air intake heater installed (more information in Electronic Sensors and
Systems).

Some future application will have an ether aid in place of the heater.
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TURBOCHARGER
COMPRESSOR OIL BEARING TURBINE TURBINE
HOUSING INLET HOUSING WHEEL
PORT

AIR EXHAUST
INLET OUTLET

OIL
COMPRESSOR OUTLET
WHEEL BEARING PORT

EXHAUST INLET

• Turbocharger The turbocharger is conventional and may be equipped with a Wastegate

components (next page).
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• Turbocharger Some C-9 applications are equipped with a turbocharger wastegate.

wastegate
If the engine is required to respond rapidly at low rpm, it may be
necessary to optimize the turbocharger for this speed. In this case, the
turbocharger may develop excessive boost at rated speed and load. Also,
the turbocharger may develop excessive speed.
• Wastegate bypasses
exhaust around the The wastegate redirects a portion of the exhaust gasses past the
turbocharger
turbocharger which effectively limits turbocharger speed and turbocharger
boost. This feature also limits cylinder pressure, thus protecting the
engine from undue stress.

The wastegate is preset at the factory and no adjustments can be made.

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VALVE SYSTEM COMPONENTS

ROCKER ARM

PUSH ROD
BRIDGE

SPRING

VALVE LIFTER

10

• Valve train The C-9 Camshaft is mounted high up in the block to reduce the size of
the pushrods and therefore reduces the reciprocating mass of the valve
• Camshaft mounted
mechanism. This feature improves the ability of the engine to sustain an
high in the block
overspeed without damage.
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11

• Air intake heater and The air intake system has a heater and a temperature sensor. The Air
temperature sensor Intake Temperature Sensor is used by the ECM in conjunction with the
Coolant Temperature Sensor to calculate the need for air intake heating.

• Heater controlled by The ECM controls the heater through a relay mounted above the intake
ECM manifold.

• System warns of high The Intake Temperature Sensor is also used by the ECM to warn the
air intake temperature operator of excessive air intake temperatures.

This view shows a Challenger C-9 installation. Other C-9 applications

will vary slightly in the sensor installation.

The Service Manual, Systems Operation section, describes the various

modes of operation of this system. A description of the operation is also
included with the Electronic Sensors and Systems portion of this STMG.
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C-9 LUBRICATION SYSTEM

HEUI PUMP

TO
TURBOCHARGER OIL COOLER
OIL
FILTER

12

• Lubrication system The lubrication system is conventional with the exception of the oil cooler
schematic which is recessed (as shown on the next page) into the cylinder block.
• HEUI oil supply Note that the lubrication oil pump provides the first stage of pressure
increase for the hydraulic pump in the HEUI system.
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13

• Lubrication system The lubrication oil supply system is shown here in this cross sectional
cross section view of the cylinder block.

• Oil cooler recessed Note the oil cooler recessed into the block. This feature reduces the
overall width of the engine and reduces the possibility of leaks.

Later engines will have a direct connection for the oil to travel across the
block above the crankshaft.
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COOLING SYSTEM
EXPANSION TANK
WATER TEMPERATURE
REGULATOR HOUSING

CYLINDER
HEAD

CYLINDER BYPASS
BLOCK HOSE

OIL WATER
COOLER PUMP RADIATOR

14

• Cooling system The system is conventional with a full flow, by-pass, outlet thermostat.
schematic
• Water pump is belt The water pump is belt driven by a pulley from the crankshaft.
driven
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15

• Fractured rod This visual shows the fractured rod. The rod is deliberately fractured
during the manufacturing process in order to provide a mating surface that
does not allow fretting or sideways movement between the two halves of
the rod.

• Use care when NOTE: Care should be taken to avoid damage to the mating faces during
handling mating handling. The rod must be replaced if there is any damage to the mating
surfaces surfaces. If the surfaces are damaged, bearing crush will be insufficient,
which can cause the bearing to spin in its bore.

• Fractured rod The fracture process involves the following steps:

manufacturing
process The bolt holes are fully drilled, and tapped prior to fracture.
The fracture process begins with rough boring the crank end prior to
fracture (approximately. 1 mm undersize).
A laser (or "V" broach) is then used to etch a "V" notch for
initiating the crack split line.
A wedge is used in a hydraulically activated expanding mandrill to
force apart the rod and cap at the split line.
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After the rod is split, the bolts are inserted and the cap reassembled.
The bolts are tightened to about 90% of final torque, backed off,
and the cap removed.
The joint is then cleaned to remove any chips that may have broken
off, before the cap and rod are reassembled and the bolts re-
tightened down again. This procedure is performed twice.
Once tightened, the cap is not separated from the rod again during
the rest of the machining process. (Note: A fixture or torque gun
would be required to loosen the bolts prior to dispatch, or during
piston sub-assembly).

The advantages associated with fracturing the split are primarily reduced
machining operations. Some examples are as follows:

No machining of joint faces necessary.

No deburring of joint face edges due to perfectly matched joint
faces.
Elimination of dowels or fitted bolts (fracture surface results in a
perfectly mated joint).
Near net shape forgings (may eliminate the need for additional
balance machining).
Single clamping fixture required for machining bolt holes (no
separate cap and rod machining - same for bearing tab slots).

The majority of the benefits with fractured split rods lie in the
manufacturing process. There are other benefits such as virtual
elimination of fretting on the joint face, with the rod being able to accept
higher loads, due to perfectly matched surfaces. In addition, one of the
reported benefits of fractured split rods is that they tend to have a higher
processing quality than conventional rods due to the reduced machining
steps and controlled machining process. From a cost standpoint, this
feature can result in a part cost that is significantly reduced.
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CRANKSHAFT OIL FLOW

OIL GALLERY

MAIN
BEARINGS
(7)
7 6 5 4 3 2 1

6 5 4 3 2 1
ROD BEARINGS (6)

16

• Crankshaft oil flow This visual shows the path of oil flow from the main bearings to the rod
bearings.

• Oil flow to rod It can be seen that three main bearings (1, 4 and 7) do not feed any rod
bearings bearings. Two more main bearings (2 and 6) supply oil to one rod bearing
each. Main bearing numbers 3 and 5 supply oil to two rod bearings each.

This information is important if a bearing failure analysis is performed.

For additional information in bearing failure analysis, please refer to the

following AFA (Applied Failure Analysis) publications:

• Related failure
STMG Engine Bearings (SERV8001)
analysis publications
Engine Bearing Failure Analysis (SEBV0544)
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VISCOUS VIBRATION DAMPER

CRANKSHAFT

WEIGHT

CASE

17

• Viscous crankshaft The viscous crankshaft vibration damper is also used to reduce crankshaft
vibration damper torsional vibrations. This damper uses a heavy ring enclosed within a
casing and suspended by a viscous oil to oppose torsional vibration
forces.
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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:

The following exercise will reinforce the material introduced in the

preceding visuals and will allow questions to be answered.

At this time, it is recommended that each component be located on the

machine and the function of each component reviewed with the students.
A list of the components follows on the next page.

If an engine is available out of a machine, component identification will

be easier because some components are difficult to see.

Some additional (used/defective) components available for examination

on a table will be helpful.

The Systems Operation portion of the Systems Operation Testing and

Adjusting manual for C-9 Industrial Engines (SENR9598-02) can be used
to supplement the Visual/Text information.
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ENGINE LAB COMPONENT LIST

Electrical Component List

ECM and 70 Pin Connectors (2)

Timing Calibration Installation Location
Timing Calibration Connector
Speed/Timing Sensors
Coolant Temperature Sensor
Intake Air Temperature Sensor
Atmospheric Pressure Sensor
Turbocharger Outlet (Intake Manifold) Pressure Sensor
Oil Pressure Sensor
Hydraulic Oil Temperature Sensors (2)
Hydraulic Oil Pressure Sensor
Fuel Temperature Sensor
Machine Interface Connector
Engine and Machine Ground Bolts
Service Tool Connector
Throttle Position Sensor
Shutdown Switches
Battery Disconnect Switch

Mechanical (Fuel Delivery) Component List

Primary Filter and Water Separator

Water in Fuel Sensor (if installed)
Secondary Filter
Priming Pump
Transfer Pump
Pressure Regulator Valve
Injectors (6)
Cylinder Head Fuel Passage
ECM Fuel Cooling Passage and Connectors (if installed)

Mechanical Component List

Thermostat
By-pass hose