Service Training

November 2001

TECHNICAL PRESENTATION

C-9 ENGINE
SYSTEMS AND CONTROLS

Caterpillar Asia Pacific Learnig-China

C-9 ENGINE
SYSTEMS AND CONTROLS SLIDES 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 Electronic Technician (ET) software. No 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. This publication is not available in paper form and is only available from the intranet at this time. Estimated Time: 8 Hours Visuals: 71 Electronic Slides Date: 11/2001
2001 Caterpillar Inc.

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SUPPLEMENTARY TRAINING MATERIAL

Brochure "Service Technician Workbench" Brochure "Caterpillar Electronic Technician" Service Technician Workbench Tutorial (Included with STW software) Caterpillar HEUI Fuel System (Interactive CD ROM) NELG0028 NEDG6015 NEHS0812 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) Engine Turning Tool Electronic Tools Laptop computer Communication Adapter II (Group) Cable, PC to Communication Adapter Cable, Communication Adapter to Machine Caterpillar Digital Multimeter Three Pin DT Breakout Harness Cable Probes Auxiliary ECM Power Supply Harness Timing Calibration Probe (Magnetic Pickup) Timing Calibration Probe Adapter Sleeve Timing Calibration Probe Cable

196-3165 9S-9082

171-4400 96-0055 160-0133 146-4080 7X-6370 7X-1710 167-9225 6V-2197 7X-1171 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 ......................................................................................................................5 Lab Exercise ...................................................................................................................21 SYSTEM POWER SUPPLIES Introduction ....................................................................................................................25 ECM Power Supply .......................................................................................................26 Injector and Compression Brake Power Supply ............................................................30 Hydraulic Pump Control Valve Power Supply ...............................................................31 Analog Sensor Power Supply ........................................................................................32 Digital Sensor Power Supply .........................................................................................33 Air Intake Heater Power Supply ....................................................................................34 Service Tool Power Supply ............................................................................................35 Lab Exercise ...................................................................................................................36 ELECTRONIC CONTROL SYSTEM Introduction.....................................................................................................................37 Fuel Injection .................................................................................................................40 Fuel Injection Control System .......................................................................................42 SYSTEM CALIBRATIONS Introduction.....................................................................................................................49 Speed/Timing Sensor Calibration ..................................................................................49 Injector Calibration ........................................................................................................54 Pressure Sensor Calibration ...........................................................................................56 Oil Grade Detection ........................................................................................................57 Lab Exercise ...................................................................................................................58 ELECTRONIC SENSORS AND SYSTEMS Introduction ....................................................................................................................59 Injector and Compression Brake Systems ......................................................................60 Speed/Timing Sensors ....................................................................................................61 Analog Sensors and Circuits ..........................................................................................64 Digital Sensors and Circuits ...........................................................................................77 Engine Shutdown Systems .............................................................................................80 Cold Starting Aids .........................................................................................................82 Data Link Circuits...........................................................................................................84 Lab Exercise ...................................................................................................................87 CONCLUSION ....................................................................................................................87 SLIDE LIST .........................................................................................................................89

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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 - Use System Operation manual for reference

INSTRUCTOR NOTE: 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 Slide/Text information. 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

EXHAUST VALVES

BORE 112 MM (4.4 IN) STROKE 149 MM (5.9 IN)

Cylinder and valve location 8.8 liters displacement Inlet and exhaust valve arrangement

The C-9 engine has an in-line six cylinder arrangement. The engine has a bore of 112 mm (4.4 in) and a stroke of 149 mm (5.9 in). The engine displacement is 8.8 liters. Note the arrangement of the inlet and exhaust valves for identification purposes.

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Major components

This view shows the some of 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. 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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4
HEUI system schematic

This visual is taken from the Caterpillar HEUI HI300B Fuel System CD RENR1392. This CD will supply all the information on the HEUI fuel system, electronics and related diagnostics. This HEUI system is very similar to the 3408E, 3412E and 3126 HEUI systems. There are a number of features which differ from other engines. The hydraulic pump is a completely new design. There are no jumper tubes on the injectors. Oil under pressure is fed directly from the cylinder head to the injectors. There are two Hydraulic Oil Temperature Sensors installed on the engine. Optional water in fuel and fuel pressure sensors may be installed in the fuel supply system.

Similar to other HEUI systems Some system differences - New HEUI hydraulic pump - No jumper tubes - Two hydraulic oil temperature sensors - Water in fuel and fuel pressure sensors available

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Cross flow cylinder head - Improves emissions and fuel consumption

The C-9 engine has a cross flow cylinder head. This feature allows for improved emissions and fuel consumption by improving the combustion airflow through the engine.

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AIR INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD

INTAKE HEATER

AIR TO AIR AFTERCOOLER

EXHAUST VALVE

INLET VALVE

AIR INLET

EXHAUST OUTLET TURBOCHARGER

COMPRESSOR TURBINE SIDE SIDE

Air intake and exhaust system schematic

The air to air aftercooler is used in most applications, the exception is the marine engine. By cooling the precharge air, this component increases the mass flow of air through the engine, thus allowing more horsepower. The air intake heater is used to aid starting and reduce white smoke in cold conditions. In most applications, the air intake heater replaces the ether aid, however in extreme cold conditions, it is possible to use the ether aid in conjunction with the air intake heater.

Air intake heater

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TURBOCHARGER
COMPRESSOR HOUSING OIL BEARING TURBINE TURBINE INLET HOUSING WHEEL PORT

AIR INLET

EXHAUST OUTLET

COMPRESSOR WHEEL

BEARING

OIL OUTLET PORT

EXHAUST INLET

Turbocharger components

The turbocharger is conventional and may be equipped with a Wastegate (next page).

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Turbocharger wastegate

Some C-9 applications are equipped with a turbocharger 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 turbo may develop excessive boost at rated speed and load.

Wastegate bypasses exhaust around the turbocharger

The wastegate redirects a portion of the exhaust gasses past the turbocharger which effectively limits turbo speed and 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

Valve train Camshaft mounted high in the block

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 mechanism. This feature improves the ability of the engine to sustain an overspeed without damage.

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10

Air intake heater and temperature sensor

The air intake system has a heater and a temperature sensor. The Air Intake Temperature Sensor is used by the ECM in conjunction with the Coolant Temperature Sensor to calculate the need for air intake heating. The ECM controls the heater through a relay mounted above the intake manifold. The Intake Temperature Sensor is also used by the ECM to warn the operator of excessive air intake temperatures. 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.

Heater controlled by ECM System warns of high air intake temperature

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C-9 LUBRICATION SYSTEM

HEUI PUMP

TO TURBOCHARGER OIL FILTER

OIL COOLER

11

Lubrication system schematic

The lubrication system is conventional with the exception of the oil cooler which is recessed (as shown on the next page) into the cylinder block.

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12

Lubrication system cross section Oil cooler recessed

The lubrication oil supply system is shown here in this cross sectional view of the cylinder block. Note the oil cooler recessed into the block. This feature reduces the overall width of the engine and reduces the possibility of leaks.

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COOLING SYSTEM
EXPANSION TANK WATER TEMPERATURE REGULATOR HOUSING CYLINDER HEAD

CYLINDER BLOCK

BYPASS HOSE

OIL COOLER

WATER PUMP

RADIATOR

13

Cooling system schematic Water pump is belt driven

The system is conventional with a full flow by-pass outlet thermostat. The water pump is belt driven by a pulley from the crankshaft.

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14

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 handling mating surfaces

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

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CRANKSHAFT OIL FLOW

OIL GALLERY

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

ROD BEARINGS (6)

15

Crankshaft oil flow

This visual shows the path of oil flow from the main bearings to the rod bearings. It can be seen that three main bearings (1, 4 and 7) do not feed any rod 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:

Oil flow to rod bearings

Related failure analysis publications

STMG Engine Bearings (SERV8001) Engine Bearing Failure Analysis (SEBV0544)

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RUBBER VIBRATION DAMPER

CRANKSHAFT RING RUBBER RING HUB

ALIGNMENT

16

Rubber crankshaft vibration damper Alignment marks for damage indication

The dampers are used to reduce crankshaft torsional vibration. This rubber crankshaft vibration damper has alignment marks to indicate the condition of the damper. Misalignment of the marks indicates that the rubber bonding between the two parts has separated.

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VISCOUS VIBRATION DAMPER

CRANKSHAFT

WEIGHT

CASE

17

Viscous crankshaft vibration damper

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

Lab exercise

Lab Exercise: The following exercise will reinforce the material introduced in the preceding slides 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 Slide/Text information.

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Electrical Component List ECM and 70 Pin Connectors (2) Timing Calibration Installation Location Timing Calibration Connector Speed Timing Sensors Coolant Temperature Sensor Inlet Air Temperature Sensor Atmospheric Pressure Sensor Turbocharger Outlet Pressure Sensor Oil Pressure Sensor Hydraulic Oil Temperature Sensors 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