C-9 ENGINE

SYSTEMS AND CONTROLS

2001 Caterpillar Inc.

 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)
 AIR INTAKE AND EXHAUST SYSTEM

EXHAUST
MANIFOLD INTAKE
AFTER COOLER
HEATER

INLET AIR EXHAUST

EXHAUST OUTLET
VALVE VALVE INLET
TURBOCHARGER
COMPRESSOR TURBINE
SIDE SIDE
 TURBOCHARGER
COMPRESSOR OIL BEARING TURBINE TURBINE
HOUSING INLET HOUSING WHEEL
PORT

AIR EXHAUST
INLET OUTLET

OIL
COMPRESSOR OUTLET
WHEEL BEARING 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

CYLINDER BYPASS
BLOCK HOSE

OIL WATER
COOLER PUMP RADIATOR
 CRANKSHAFT OIL FLOW

OIL GALLERY

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

6 5 4 3 2 1
ROD BEARINGS (6)
 RUBBER VIBRATION DAMPER

CRANKSHAFT RING

RUBBER RING

HUB

ALIGNMENT
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
6 DRIVERS BOLT

DISCONNECT SWITCH
3 RETURNS 24 V

ENGINE RETARDER 20 AMP FUSE

SOLENOIDS 20 AMP
BREAKER
MAIN
TIMING CALIBRATION POWER
CONNECTOR KEY START
RELAY
SWITCH

CRANK WITHOUT INJECT PLUG

 ECM POWER SUPPLY CIRCUIT

BATTERY ENGINE BLOCK

GROUND BOLT P1 J1 ECM (C-9)
(-) 61 (-) BATTERY
63 (-) BATTERY
24 VOLTS DC
65 (-) BATTERY
(+) 20 A 48 (+) BATTERY
52 (+) BATTERY
DISCONNECT FUSE
53 (+) BATTERY
SWITCH
70 (+) SWITCHED POWER
WIRE FUNCTION COLOR CODE
(+) BATTERY SUPPLY WIRES
INPUT SIGNAL WIRES TO ECM
R
OUTPUT SIGNAL WIRES FROM ECM
15 AMP C OFF
SENSOR SUPPLY VOLTAGE
CIRCUIT BREAKER S ON
SIGNAL PLUS
B ST
SIGNAL MINUS
KEY SWITCH
(-) BATTERY / SENSOR RETURN
 ECM CONNECTOR (P1)

1 2 3 4 5 6 8 9 10 11 12 13
13 1

23 14 14 >PEI< 23
31 24
24 31
39 32 36
47 40 40 47
57 48 48 57

70 58
58 59 60 61 62 63 65 66 67 68 69 70

ECM SIDE HARNESS SIDE

 INJECTOR AND COMPRESSION BRAKE
SOLENOID CIRCUITS
2 12 20 BRAKE RETURN CYL 1
1 1 36 INJECTOR/BRAKE CYL 1
18 44 INJECTOR RETURN CYL 1
2 11 21 BRAKE RETURN CYL 2
BRAKE 1 2 37 INJECTOR/BRAKE CYL 2
SOLENOID 17 45 INJECTOR RETURN CYL 2
CYL. 1 2 10 28 BRAKE RETURN CYL 3
BRAKE 1 3 38 INJECTOR/BRAKE CYL 3
SOLENOID 16 46 INJECTOR RETURN CYL 3
J301 P301 CYL. 2 2 9 29 BRAKE RETURN CYL 4
1 BRAKE 1 4 39 INJECTOR/BRAKE CYL 4
2 SOLENOID 15 47 INJECTOR RETURN CYL 4
J302 P302 CYL. 3 2 8 65 BRAKE RETURN CYL 5
1 BRAKE 1 5 54 INJECTOR/BRAKE CYL 5
2 J303 P303 SOLENOID 14 67 INJECTOR RETURN CYL 5
CYL. 4 2 7 66 BRAKE RETURN CYL 6
1
2 BRAKE 1 6 55 INJECTOR/BRAKE CYL 6
J304 P304 SOLENOID 13 68 INJECTOR RETURN CYL 6
CYL. 5
1 BRAKE P300 J300 P2 J2 ECM
2 SOLENOID
J305 P305 CYL. 6
INJECTOR 1
SOLENOID 2 J306 P306
CYL. 1 1
INJECTOR 2
SOLENOID
CYL. 2 INJECTOR
SOLENOID
CYL. 3
INJECTOR
SOLENOID
CYL. 4
INJECTOR
SOLENOID
CYL. 5
INJECTOR
SOLENOID
CYL. 6
 PUMP CONTROL VALVE
POWER SUPPLY

PUMP CONTROL
VALVE J500 P500
P2 J2 ECM (C-9 HEUI)
SUPPLY A 61 + CONTROL VALVE
RETURN B 62 - CONTROL VALVE
 ANALOG SENSOR
J200/P200
POWER SUPPLY CIRCUIT
TURBO OUTLET PRESSURE SIGNAL C 5 0.5 VOLTS
ANALOG SENSOR RETURN 3 B
ANALOG SENSOR POWER (+5V) 3 A
P2 J2 ECM
J204/P204
HYDRAULIC OIL PRESSURE SIGNAL C 40 TURBO OUTLET PRESSURE SIGNAL
ANALOG SENSOR RETURN 1 B 27 HYDRAULIC OIL PRESSURE SIGNAL
ANALOG SENSOR POWER (+5V) 1 A

J203/P203
ATMOSPHERIC PRESSURE SIGNAL C 14 ATMOSPHERIC PRESSURE SIGNAL
ANALOG SENSOR RETURN 1 B 3 ANALOG SENSOR RETURN 1
ANALOG SENSOR POWER (+5V) 1 A 2 ANALOG SENSOR POWER (+5V) 1

J209/P209
FUEL PRESSURE SIGNAL C 18 FUEL PRESSURE SIGNAL
ANALOG SENSOR RETURN 1 B
ANALOG SENSOR POWER (+5V) 1 A

J201/P201
ENGINE OIL PRESSURE SIGNAL C 24 ENGINE OIL PRESSURE SIGNAL
ANALOG SENSOR RETURN 3 B 42 ANALOG SENSOR RETURN 3
ANALOG SENSOR POWER (+5V) 3 A 41 ANALOG SENSOR POWER (+5V) 3
 THROTTLE
POSITION SENSOR
J405 P405 P1 J1 ECM (C-9 HEUI)
+V DIGITAL A 4 + V DIGITAL SUPPLY
DIGITAL RETURN B 5 - V DIGITAL RETURN
SIGNAL C

FAN DIGITAL SENSOR

SPEED SENSOR POWER SUPPLY CIRCUIT
+V DIGITAL A 8 0.5 VOLTS
DIGITAL RETURN B
SIGNAL C
 AIR INTAKE HEATER CIRCUIT

AIR INTAKE
HEATER LAMP

24V

J648

A
B
P648
AIR INTAKE AIR INTAKE
HEATER HEATER RELAY

J501 P501
ECM
1
2 AIR INTAKE
850-BU 1
HEATER RELAY
 TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT
CATERPILLAR
TRANSMISSION ECM MONITORING SYSTEM

CAT DATA LINK + 8 8 CAT DATA LINK +

CAT DATA LINK - 7 7 CAT DATA LINK -

J63 P1 J1 ENGINE ECM

A 70 BAT + (SWITCHED)
B 65 BAT -
C
D 8 CAT DATA LINK +
E 9 CAT DATA LINK -
F 34 CAN DATA LINK -
G 50 CAN DATA LINK +
SERVICE TOOL
CONNECTOR
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 TIMING DEGREES BTDC DESIRED
FUEL RPM TIMING FUEL INJECTION
FUEL QUANTITY BTDC CONVERT TIMING WAVE FORM
SELECT
TIMING DESIRED
TIMING
HYDRAULIC OIL
TEMPERATURE
 C-9
ELECTRONIC GOVERNOR HYDRAULIC OIL
SHUTDOWNS TEMPERATURE AND
PRESSURE SENSORS
ECM
TO PUMP
CONTROL ELECTRONIC
VALVE GOVERNOR
6
5 AFRC TORQUE
SIGNALS FUEL ENGINE THROTTLE
TO FUEL 4 INJECTION ENGINE RPM MAPS MAPS CONTROL
INJECTORS 3 CONTROL LOGIC
2 TDC
1

SPEED/TIMING ENGINE RPM ENGINE RPM

SIGNAL
SPEED/TIMING TURBO OUTLET AND
SENSORS ATMOSPHERIC
TIMING PRESSURE SENSORS
WHEEL
 C-9 SPEED/TIMING SENSORS
UPPER (HIGH SPEED)
SPEED/TIMING
SENSOR J401/P401
1
2 J2/P1 ECM

49 - UPPER S/T SENSOR

48 + UPPER S/T SENSOR
LOWER (CRANKING)
SPEED/TIMING
SENSOR J402/P402

1 59 - LOWER S/T/ SENSOR

2 58 + LOWER S/T SENSOR

1 22 + TIMING CAL PROBE

2 23 - TIMING CAL PROBE
 GEAR TRAIN SHOWN
SPEED/TIMING SENSING
FROM FRONT OF ENGINE 45 CRANK DUAL PASSIVE SENSORS
UPPER
SPEED/TIMING SENSOR A
(75 TO 230 OHMS)

LOWER
SPEED/TIMING SENSOR B
(600 TO 1800 OHMS)

SENSOR A
CAMSHAFT MEASURED TDC NO.1 45 CRANK
IDLER
SENSOR B
GEAR LOWER SENSOR UPPER SENSOR
MEASURED TDC NO.1
LOW SPEED HIGH SPEED
15 CRANK 30 CRANK
CRANKSHAFT
GEAR GEAR
ROTATION

SENSOR B SENSOR A SENSOR B SENSOR A

TDC NO.1 TDC NO.1 TDC NO.5 TDC NO.5

SENSOR
SIGNALS

UPPER SENSOR A TIMING -90 -60 -30 0 30 45 60 90

LOWER SENSOR B TIMING -70 -45 -15 -0 15 45 75 90 105
 C-9 TIMING CALIBRATION
PROBE INSTALLATION

TDC POSITION
CRANKSHAFT
COUNTERWEIGHT

MACHINED FACE

DIRECTION OF
ROTATION

TIMING CALIBRATION PROBE

POSITIONED 85 CRANKSHAFT ENGINE BLOCK
DEG. AFTER TDC (SHOWN FROM REAR)

TIMING CALIBRATION AIR GAP

SLOT 1 mm (.040 in)
 C-9 TIMING CALIBRATION

TIMING
WHEEL

REFERENCE EDGE TO TDC DISTANCE

REFERENCE
EDGE ASSUMED ACTUAL
CYL. NO. 1 TDC CYL. NO. 1 TDC

-3 +3
TIMING REFERENCE
TIMING CALIBRATION
OFFSET
SENSOR SIGNAL
(MAXIMUM RANGE
3 DEGREES)
25 ENGINE DEGREES
 C-9 SPEED/TIMING SENSORS CALIBRATION
UPPER (HIGH SPEED)
SPEED/TIMING
SENSOR J401/P401
1
2 J2/P1 ECM

49 - UPPER S/T SENSOR

48 + UPPER S/T SENSOR
LOWER (CRANKING)
SPEED/TIMING
SENSOR J402/P402

1 59 - LOWER S/T/ SENSOR

2 58 + LOWER S/T SENSOR

TIMING CALIBRATION
PROBE J400/P400
1 22 + TIMING CAL PROBE
2 23 - TIMING CAL PROBE
TIMING CALIBRATION
CONNECTOR
ELECTRONIC SENSORS
AND
SYSTEMS
 ECM J2 J1

6 INJECTOR SOLENOIDS

6 COMPRESSION
BRAKE SOLENOIDS
 ECM J2 J1

6 INJECTOR SOLENOIDS

6 COMPRESSION
BRAKE SOLENOIDS

TIMING CALIBRATION
CONNECTOR
 ECM J2 J1

6 INJECTOR SOLENOIDS

6 COMPRESSION
BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING
SENSORS
 ANALOG SENSORS
Coolant temperature
Air intake temperature
Hydraulic oil temperature
Hydraulic oil pressure
Atmospheric pressure
Turbocharger outlet pressure
Lubrication oil pressure
 ECM J2 J1

6 INJECTOR SOLENOIDS

6 COMPRESSION
BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING
SENSORS

COOLANT TEMP. SENSOR

 ECM J2 J1

6 INJECTOR SOLENOIDS

6 COMPRESSION
BRAKE SOLENOIDS

TIMING CALIBRATION CONNECTOR

ENGINE SPEED/TIMING
SENSORS

COOLANT TEMP. SENSOR

AIR INTAKE TEMP. SENSOR

 ECM J2 J1

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 POWER DERATING MAP
ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500

8,210
PERCENT OF FULL LOAD POWER

98%

96% 8,920

94% 9,630

10,340

ALTITUDE IN FEET
92%

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

 ECM J2 J1

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 INLET PRESSURE SENSOR

TURBO OUTLET PRESSURE SENSOR (BOOST)

 ECM J2 J1

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 INLET PRESSURE SENSOR

TURBO OUTLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

 OIL PRESSURE MAP
OIL PRESSURE WARNING AND DERATE TRIP POINTS
190 27.6

180 175 kPa (25 psi) RESET LINE 26.1

170 24.7

160 23.2

150 154 kPa (22 psi) TRIP LINE 21.8

140 20.3
130 125 kPa (18 psi) RESET LINE 18.9

OIL PRESSURE IN PSI

OIL PRESSURE IN kPa

120 17.4
110 16.0

100 104 kPa (15 psi) TRIP LINE 14.5

90 13.1

80 11.6

70 10.2

60 LOW OIL PRESSURE WARNING 8.7

50 7.3
VERY LOW OIL PRESSURE DERATE
40 5.8

30 4.4

20 2.9
10 1.5
0 0

400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2200

ENGINE RPM
kPa x 0.145 = PSI
 ECM J2 J1

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 INLET PRESSURE SENSOR

TURBO OUTLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

FUEL PRESSURE SENSOR

 ECM J2 J1

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 INLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

OIL VISCOSITY SELECTION CONNECTOR

 ECM J2 J1

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 INLET PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

FUEL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSORS

HYDRAULIC OIL PRESS. SENSORS

DIGITAL SENSORS AND CIRCUITS

Throttle Position Sensor

Fan Speed Sensor
J2 J1 ECM

GROUND DISCONNECT SWITCH

BOLT

24 V

20 AMP FUSE
20 AMP
BREAKER

MAIN
POWER
RELAY KEY
SWITCH
 PULSE WIDTH MODULATED SIGNALS
10%
ON

DUTY = 10%
CYCLE

OFF

50%
ON

DUTY = 50%
CYCLE

OFF
1 CYCLE
90%
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 P1 J1 ECM
1
2 GND. LEVEL SHUTDOWN (NO)
2
8 GND. LEVEL SHUTDOWN (NC)
3 29 DIGITAL RETURN
 USER DEFINED SHUTDOWN CIRCUIT

P1 J1
ECM

USER SHUTDOWN 59 USER DEFINED SHUTDOWN

DEVICE 5 DIGITAL RETURN
 AIR INTAKE HEATER CIRCUIT

AIR INTAKE
HEATER LAMP

24V

J648

A
B
P648
AIR INTAKE AIR INTAKE
HEATER HEATER RELAY

J501 P501
ECM
1
2 AIR INTAKE
850-BU 1
HEATER RELAY
 CAT DATA LINK
160-0133
UNIVERSAL 160-0141
DATA LINK SERIAL CABLE
CABLE (2 FT.) (25 FT.)
J2 J1
PC SERIAL PORT
(COMM PORT)
SERVICE
COMMUNICATION
TOOL
ADAPTER II
ENGINE CONNECTOR CAT
171-4400 (GP) ELECTRONIC TECHNICIAN
ELECTRONIC CONTROL
MODULE (ECM) LAPTOP
COMPUTER

P
15 AUT

10 20

TRANSMISSION 5
25

ELECTRONIC CONTROL R
X100

0 44
MODULE 24 V
MPH
km/h
30

CATERPILLAR MONITORING SYSTEM

DISPLAY UNIT
 TYPICAL CAT / CAN DATA LINK CIRCUIT
CATERPILLAR
TRANSMISSION ECM MONITORING SYSTEM

CAT DATA LINK + 8 8 CAT DATA LINK +

CAT DATA LINK - 7 7 CAT DATA LINK -

J63 P1 J1 ENGINE ECM

A 70 BAT + (SWITCHED)
B 65 BAT -
C 42 SHIELD
D 8 CAT DATA LINK +
E 9 CAT DATA LINK -
F 34 CAN DATA LINK -
G 50 CAN DATA LINK +
SERVICE TOOL
CONNECTOR