Service Training SERH4050

Instructor Materials May 2003

LAB EXERCISES

C-9 ENGINE
SYSTEMS AND CONTROLS
 C-9 LAB EXERCISES

(Instructor's Copy)

Index of Labs

Lab A: C-9 Systems Component Identification

Lab B: C-9 Systems Operation

Lab C: Fuel Injection System Component Removal and Installation

Lab D: Fuel Injection System Testing and Adjusting

Lab E: Electrical/Electronic Component Removal and Installation

Lab F: Electronic System Power Supply Testing

Lab G: Electrical/Electronic Component Testing and Adjusting

Lab H: General System Diagnostics

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Lab A: C-9 Systems Component Identification

Shop Exercise
INSTRUCTOR NOTE
Using the lab worksheets and the system schematics, identify the
EXERCISE
following components where visible:

Cooling System
Thermostat and housing
Coolant temperature sensor
Water pump
Bypass line

Lubrication System
Oil pressure sensor
Oil pump
Oil filter
Oil cooler
Oil breather

Air Intake and Exhaust System

Atmospheric pressure sensor
Turbocharger outlet pressure sensor
Intake manifold heater and relay
Air filters
Turbocharger compressor
Turbocharger turbine
Wastegate, if installed

Fuel Delivery System

Unit injector
Transfer pump
Priming pump
Primary filter
Water separator
Secondary filter
Fuel pressure regulating valve
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Lab A: C-9 Systems Component Identification (continued)

Electronic Control System
ECM and 70 pin connectors
Personality module
Speed/timing sensors
HEUI hydraulic pump
Pump control valve
Hydraulic pressure sensor
Analog and digital sensors
Electronic unit injector
Service tool connector
Machine interface connector
System power supplies
Data links
Shutdown systems
System power supplies
Ground stud

After component identification, have the class state the function and
MATERIALS NEEDED location of each component listed on the worksheet either written or
orally. All engine locations are referenced from the rear of the engine.
C-9 engine or
Machine or truck with C-9 engine
Cooling, lubrication, air intake and exhaust system schematics
Lab A Worksheets
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Lab A Worksheets--Answers

COOLING SYSTEM

_____ Thermostat and Housing

Function: Maintains the correct coolant working temperature

Location: On the upper front part of the cylinder head

_____ Coolant Temperature Sensor

Function: Sends a coolant temperature signal to the ECM

Location: Front of cylinder head

_____ Water pump

Function: Circulates coolant throughout the engine

Location: Front of cylinder block, right side, belt driven

_____ Bypass Line

Function: Allows coolant to bypass the radiator

Location: Between thermostat and water pump

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Lab A: Worksheets--Answers

LUBRICATION SYSTEM

_____ Oil pressure Sensor

Function: Sends an oil pressure signal to the ECM

Location: Oil breather housing

_____ Oil pump

Function: Supplies oil to the lubrication and HEUI systems

Location: Lower block, in the oil pan

_____ Oil filter

Function: Filters oil down to 10 microns

Location: Right front side of engine block

_____ Oil cooler

Function: Cools (primarily) or warms the oil depending on the oil temperature

Location: In the block, right side, behind oil filter housing

_____ Oil breather

Function: Remove oil fumes and separates oil droplets

Location: Left side of block

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Lab A: Worksheets--Answers

AIR INTAKE AND EXHAUST SYSTEM

_____ Atmospheric Pressure Sensor

Function: Facilitates altitude derate, pressure sensor calibration, gauge pressure calculation

Location: Valve cover base, left side

______ Manifold (Turbocharger Outlet) Pressure Sensor

Function: Signals manifold pressure measurement to ECM for air/fuel ratio control

Location: Left side of cylinder head, in inlet manifold

_____ Inlet Manifold Heater and Relay

Function: Warms inlet air to facilitate cold starting and running. Reduces white smoke

Location: Left side of cylinder head, between inlet manifold and inlet duct

_____ Turbocharger Compressor

Function: Boosts air inlet pressure above atmospheric, improves cylinder volumetric efficiency

Location: Turbocharger inlet

_____ Turbocharger Turbine

Function: Uses waste exhaust gas gas energy to drive turbo compressor

Location: Turbocharger exhaust

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Lab A: Worksheets--Answers

FUEL DELIVERY SYSTEM

_____ Transfer Pump

Function: Supplies fuel to the injectors

Location: Mounted on the rear of the HEUI pump

_____ Priming Pump

Function: Used to fill system and remove air

Location: Usually located on the primary filter

_____ Primary Filter and Water Separator

Function: Removes particles down to 10 microns, protects the transfer pump from dirt particles

Location: Typically left front side, varies with application

_____ Secondary Filter

Function: Removes particles down to 2 microns, protects unit injectors from dirt particles

Location: Usually on left side of engine, depending on application

_____ Unit Injector

Function: Atomizes and delivers fuel to the combustion chamber

Location: Cylinder head, in combustion chamber

_____ Fuel Pressure Regulating Valve

Function: Maintains system pressure in cylinder head fuel supply manifold

Location: At rear of cylinder head, may vary with application

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Lab A: Worksheets--Answers

FUEL DELIVERY SYSTEM

_____ Cylinder Head Fuel Passage

Function: Provides fuel for unit injectors

Location: Runs longitudinally through cylinder head

_____ ECM Fuel Cooling Passage (if so equipped)

Function: Cools injector drivers within the ECM

Location: In ECM casing

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Lab A: Worksheets--Answers

FUEL CONTROL SYSTEM

_____ ECM and 70 Pin Connectors

Function: Fuel system controller computer

Location: On left side of engine

_____ HEUI Hydraulic Pump

Function: Used to actuate the hydraulic unit injectors

Location: Left side of engine, on the rear of the timing gear housing

_____ Hydraulic Pump Control Valve (IAPCV)

Function: Used by the ECM to control pump displacement and pressure

Location: On top of hydraulic pump

_____ Hydraulic Manifold

Function: Used to deliver hydraulic oil to the unit injectors

Location: Integral in the left side of cylinder head

_____ Hydraulic Pressure Sensor

Function: Used by the ECM to measure pump pressure

Location: On cylinder head, left side, in hydraulic manifold

_____ Hydraulic Oil Temperature Sensors

Function: Used by ECM to correct injector timing with temperature related viscosity changes

Location: On cylinder head, left side, in hydraulic manifold

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Lab A: Worksheets--Answers

FUEL CONTROL SYSTEM

_____ Speed/Timing Sensors

Function: Upper and lower; measures engine speed, crankshaft position, cylinder identification

Location: Behind timing cover, below the hydraulic pump

_____ Timing Wheel

Function: Used by the speed/timing sensors to measure crankshaft speed and position

Location: Mounted on the front of the camshaft. Is part of the gear

_____ Timing Calibration Probe

Function: Corrects slight timing errors on the speed/timing sensors

Location: May be installed on the cylinder block, lower left side

_____ Throttle Position Sensor

Function: Provides a digital signal of the throttle pedal/lever position to the ECM

Location: Attached to the throttle pedal or throttle lever

_____ Shutdown Switch

Function: Machines; provides a means to shut down the engine without mounting the machine

Location: Usually at ground level, depending on machine application

_____ User Defined Shutdown

Function: Machines; allows a customer installed device to shut down the engine

Location: Customer installed circuit connects to terminal on the ECM 70 pin connector
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Lab A Worksheets--Answers

FUEL CONTROL SYSTEM

_____ CAT Data Link

Function: Links all on board ECMs computers and the ET Service Tool

Location: Wiring harness

_____ CAN Data Link

Function: Connects on board components and the Service Tool for programming

Location: Wiring harness

_____ Service Tool Connector

Function: Connects the computer with the ET Service Tool to the the data links and ECMs

Location: On machines, in the cab, depending on the application

_____ Analog Power Supply

Function: Powers active pressure sensors

Location: Internal, part of ECM

_____ Digital Power Supply

Function: Powers the throttle position sensor and future digital sensors

Location: Internal, part of ECM

_____ Ground Stud

Function: Provides a ground for the ECM and related circuits

Location: On the cylinder head, left side, above the ECM

SERH4050 - 13 - Laboratory Exercises
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Lab B: C-9 Systems Operation

INSTRUCTOR NOTE
Shop Exercise
Using the system schematics, trace the flow through the systems and
EXERCISE
identify the following components on the schematics:

Cooling System
Thermostat and housing
Coolant temperature sensor
Water pump
Bypass line

Lubrication System
Oil pressure sensor
Oil pump
Oil filter
Oil cooler
Oil breather

Air Intake and Exhaust System

Atmospheric pressure sensor
Manifold (turbocharger outlet) pressure sensor
Inlet manifold heater and relay
Air filters
Turbocharger compressor
Turbocharger turbine
Wastegate, if installed

Fuel Delivery System

Unit injector
Transfer pump
Priming pump
Primary filter
Water separator
Secondary filter
Fuel pressure regulating valve
SERH4050 - 14 - Laboratory Exercises
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Lab B: C-9 Systems Operation (continued)

Electronic Control System
ECM and 70 pin connectors
Personality module
INSTRUCTOR NOTE
Speed/timing sensors
EXERCISE
HEUI hydraulic pump
Pump control valve
Hydraulic pressure sensor
Analog and digital sensors
Electronic unit injector
Service tool connector
Machine interface connector
System power supplies (7)
Data links (2)
Shutdown systems
Ground stud

MATERIALS NEEDED
Cooling, lubrication, air intake, exhaust, fuel system and electronic
systems schematics
SERH4050 - 15 - Laboratory Exercises
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Lab C: Fuel Injection System Component Removal and

Installation

INSTRUCTOR NOTE Shop Exercise

EXERCISE Remove and install the following components following service manual
procedures:

Transfer Pump

Fuel Pressure Regulating Valve

Primary Filter

Secondary Fuel Filter

Hydraulic Unit Injector

Hydraulic (HEUI) Pump

INSTRUCTOR NOTE: Stress the importance of NOT filling the

filter prior to installation.

MATERIALS NEEDED A machine or truck with a C-9 Engine and/or C-9 engine
Fuel Supply Circuit Schematic and sectional views (See Student
Materials)
PC with ET/STW software installed
Engine Service Manual
Communication Adapter and Cables
Caterpillar Multimeter
Injector removal installation tool
Mechanic's tool box with hand tools
SERH4050 - 16 - Laboratory Exercises
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Lab D: Fuel Injection System Testing and Adjusting

INSTRUCTOR NOTE Class or Shop Lab Exercise--This lab will verify that the students have the
necessary skills to test the components after removal and installation.

Review the tasks before starting the exercise. The tasks in this portion of
the lab can be demonstrated on a C-9 powered machine or truck or an
industrial engine. The use of an additional large screen computer monitor
or overhead LCD projector is recommended so that all students can see
the ET screens.

NOTE: Although helpful tips are provided to facilitate the labs, the
Service Manual must be the final authority and source of information
for the procedures.

The cylinder cutout tests can be performed on a training engine with

acceptable results. However, it is also recommended that the exercise be
demonstrated on a machine or truck with load applied. An open and a
short circuit should be created in the injector circuit prior to the lab.

EXERCISE Demonstrate the following:

Input injector trim codes using ET

Retrieve Active and Logged Faults for injectors
Injector Solenoid Test
Manual Cylinder Cutout Test with no load
Manual Cylinder Cutout Test with a constant load applied
Automatic Cylinder Cutout Test
Cylinder Cutout with torque stall test
Injector Actuation Pressure Test

MATERIALS NEEDED
A machine or truck with a C-9 Engine and/or C-9 engine
PC with ET/STW software installed
Engine Service Manual
Communication Adapter and Cables
Caterpillar Multimeter
Injector removal installation tool
Mechanic's tool box with hand tools
Lab D Worksheets
SERH4050 - 17 - Laboratory Exercises
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LAB D: HEUI INJECTOR TEST WORKSHEET

C-9 ENGINE APPLICATION: ENGINE SERIAL NO:

INJECTOR ACTIVE FAULTS

INJECTOR LOGGED FAULTS

INJECTOR TEST
SOLENOID MANUAL CYLINDER AUTO CYLINDER
TEST CUTOUT TEST RPM CUTOUT TEST
COOLANT
CYLINDER OPEN/SHORT/OK NO LOAD FULL LOAD RESULTS
TEMP

RETEST

6
10/01 - 18 - Laboratory Exercises

LAB D: C-9 HYDRAULIC SYSTEM TEST WORKSHEET

C-9 ENGINE APPLICATION:

ENGINE SERIAL NO:

INJECTOR ACTUATION PRESSURE TEST

DESIRED ACTUAL COOLANT

TEST % LOAD RPM % CURRENT
PRESSURE PRESSURE TEMP

MANUAL NO LOW IDLE

MANUAL NO HIGH IDLE

MANUAL FULL MAXIMUM

INJECTOR ACTUATION PRESSURE RETEST

DESIRED ACTUAL COOLANT

TEST % LOAD RPM % CURRENT
PRESSURE PRESSURE TEMP

MANUAL NO LOW IDLE

MANUAL NO HIGH IDLE

MANUAL FULL
SERH4050 - 19 - Laboratory Exercises
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Lab E: Electrical/Electronic Component Removal and

Installation
Class or Shop Lab Exercise--Students will use the procedures provided in
INSTRUCTOR NOTE
the Student Materials to complete the exercise.

Review the tasks before each student starts the exercise. All the tasks in
this lab can be demonstrated on an operable training engine or on a C-9
powered machine or truck. Each student should demonstrate competence
in all tasks in this lab.

NOTE: Although helpful tips are provided to facilitate the labs, the
Service Manual must be the final authority and source of information
for the procedures.

Students will remove and install the following components:

EXERCISE

Pressure Sensors
Temperature Sensor
Throttle Position Sensor
Speed/Timing Sensors
ECM

MATERIALS NEEDED Engine Service Manual

An operable training engine and/or a C-9 powered machine or truck
PC with ET/STW software installed
Communication Adapter and Cables
Caterpillar Multimeter
Mechanic's tool box with hand tools
SERH4050 - 20 - Laboratory Exercises
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Lab F: Electronic System Power Supply Testing

INSTRUCTOR NOTE
Class or Shop Lab Exercise--Students will use the procedures provided in
the Student Materials to complete the exercise.

Review the tasks before each student starts the exercise. All the tasks in
this lab can be demonstrated in the classroom with a training aid, on an
operable training engine or on a C-9 powered machine or truck.

Each student should demonstrate competence in all tasks in this lab.

EXERCISE Test the following power supply circuits following the service manual
procedures:

ECM power supply

HEUI pump control valve
Analog sensor power supply
Digital sensor power supply
Air Intake heater power supply
Service tool power supply

The injector power supply can be verified by the solenoid test or any of
the injector tests.
The pump control valve power supply can be verified using the ET
injection actuation pressure test. Also use the status screen and check the
current flow through the solenoid.

MATERIALS NEEDED Service literature (see Preparation Checklist)

An operable training engine and/or a C-9 powered machine or truck
PC with ET/STW software installed
Caterpillar Multimeter
Mechanic's tool box with hand tools
Lab F Worksheet
SERH4050 - 21 - Laboratory Exercises
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LAB F: POWER SUPPLY TEST WORKSHEET

C-9 ENGINE APPLICATION

ENGINE SERIAL NO:

POWER SUPPLY ACTIVE FAULTS

POWER SUPPLY LOGGED FAULTS

POWER SUPPLY VOLTAGE CHECKS

SPEC ACTUAL
POWER SUPPLY TEST RESULTS
VOLTAGE VOLTAGE

MIN
ECM
MAX

ANALOG MIN
MAX

DIGITAL MIN
MAX
INTAKE MIN
HEATER MAX

SERVICE MIN
TOOL MAX

ANALYSIS
SERH4050 - 22 - Laboratory Exercises
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Lab G: Electrical/Electronic Component Testing and

Adjusting
Class or Shop Lab Exercise--Students will use the procedures provided in
INSTRUCTOR NOTE
the Student Materials to complete the exercise.

Review the tasks before each student starts the exercise. All the tasks in
this lab can be demonstrated in the classroom with a training aid, on an
operable training engine or on a C-9 powered machine or truck. The use
of an additional computer monitor or overhead LCD projector is
recommended so that all students can see the ET screens.

Each student should demonstrate competence in all tasks in this lab.

NOTE: Although helpful tips are provided to facilitate the labs, the
Service Manual must be the final authority and source of information
for the procedures.

EXERCISE Students will perform a diagnostic test on the following components:

Pressure Sensors (perform calibration using two methods)

Temperature Sensor
Throttle Position Sensor
Speed/Timing Sensors (perform calibration)
ECM (program with new personality module flash file)

MATERIALS NEEDED Engine Service Manual

An operable training engine and/or a C-9 powered machine or truck
PC with ET/STW software installed
Communication Adapter and Cables
Caterpillar Multimeter
Mechanic's tool box with hand tools
Lab G Worksheets
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LAB G: ANALOG SENSOR TEST WORKSHEET

C-9 ENGINE APPLICATION:

ENGINE SERIAL NO:

SENSOR ACTIVE FAULTS

SENSOR LOGGED FAULTS

PRESSURE SENSOR TEST

ABSOLUTE SIGNAL POWER

SENSOR SUPPLY RESULTS
PRESSURE VOLTS
VOLTS

ATMOSPHERIC

INTAKE
MANIFOLD

LUBE OIL

HYDRAULIC
OIL

TEMPERATURE SENSOR TESTS

TEMPERATURE
SENSOR TEST RESULTS
READING

COOLANT

OIL

INLET AIR
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LAB G: DIGITAL SENSOR TEST WORKSHEET

C-9 ENGINE APPLICATION:

ENGINE SERIAL NO:

SENSOR ACTIVE FAULTS

SENSOR LOGGED FAULTS

DIGITAL SENSOR TEST

POWER
% THROTTLE % DUTY SIGNAL SIGNAL
SENSOR SUPPLY
POSITION CYCLE FREQUENCY VOLTS
VOLTS
THROTTLE
POSITION
LOW IDLE
THROTTLE
POSITION
HIGH IDLE

TEST
RESULTS
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LAB G: SPEED/TIMING SENSOR TEST WORKSHEET

C-9 ENGINE APPLICATION

ENGINE SERIAL NO:

SENSOR ACTIVE FAULTS

SENSOR LOGGED FAULTS

SPEED/TIMING SENSOR TEST

VOLTS VOLTS
CRANKING RPM ENGINE ENGINE RESULTS
SENSOR
INDICATION STOPPED RUNNING

UPPER

LOWER

TIMING CALIBRATION

SPEED/TIMING SENSORS CALIBRATED

LIST ACTIVE FAULTS (if any)

SERH4050 - 26 - Laboratory Exercises
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LAB G: REMOVE AND REPLACE ECM

INSTRUCTION RESULTS

C-9 ENGINE APPLICATION

ENGINE SERIAL NO:

ECM PART NO.

FLASH FILE PART NO. (ORIGINAL)

FLASH FILE PART NO. (LATEST)

COPY CONFIGURATION

FLASH ECM WITH LATEST FLASH FILE

CHECK ACTIVE AND LOGGED FAULTS

PERFORM ENGINE FUNCTIONAL TEST

CHECK ACTIVE AND LOGGED FAULTS

PERFORM ENGINE ANALYSIS

SERH4050 - 27 - Laboratory Exercises
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Lab H: General System Diagnostics

INSTRUCTOR NOTE The purpose of this lab is to evaluate the student's ability to identify the
source of low power and failure to start problems and to determine
whether the fault is in the electronics or the mechanical parts of the HEUI
system.

Shop Lab Exercise--Students will use the procedures provided in the

Student Materials to complete the exercises.

Review the tasks before each student starts the exercise. All the tasks in
this lab should be demonstrated on a C-9 powered machine or truck.

Each student should demonstrate competence in all tasks in this lab.

EXERCISE Students will perform diagnostic evaluations on the following circuit

conditions/faults:

Coolant temperature open or short

Oil pressure signal open
Low hydraulic pressure
Injector open or short
Analog sensor power supply fault
Air Intake Manifold pressure sensor fault

MATERIALS NEEDED C-9 powered machine or truck

Engine Service Manual
PC with ET/STW software installed
Communication Adapter Group
Caterpillar Multimeter
Mechanic's tool box with hand tools
Lab H Worksheets
SERH4050 - 28 - Laboratory Exercises
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LOW POWER OR FAILURE TO START COMPLAINTS

Review the low power or failure to start diagnostic procedures in the Troubleshooting Guide before
conducting the lab.

The first task is to determine the source of the problem (machine/ truck or engine). Then, if the problem
is in the engine, determine if it is electronic or mechanical.

A number of checks can identify if the engine is, or is not, the root cause:

Actual engine rpm and desired engine speed.

Caterpillar Monitoring System Check Engine Lamp for HEUI system faults.
Derate for Automatic Altitude Compensation.
Air/Fuel Ratio Control derate.
Check manifold pressure at full power and compare with normal boost in similar conditions.
Check "fuel" position (synonymous with rack) on ET and compare with rated fuel.

The combination of any or all of the following faults can be used to create and troubleshoot a low power
or failure to start problem:

Injector open or short

Analog sensor power supply fault
Boost pressure sensor fault
Injector fault
Coolant/oil temperature low
Hydraulic pressure sensor fault
Hydraulic leak
Pump control valve fault

At the end of the session, students should describe why the engine has a low power problem or failure to
start problem with each of the above faults.
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LAB H: NO START SYSTEM DIAGNOSTIC WORKSHEET

C-9 ENGINE APPLICATION:

ENGINE SERIAL NO:

CHECK LIST (TROUBLESHOOTING GUIDE)

NO. TEST (P-301) RESULT CORRECTION

10

11

12
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LAB H: LOW POWER DIAGNOSTIC WORKSHEET

C-9 ENGINE APPLICATION:

ENGINE SERIAL NO:

CHECK LIST (TROUBLESHOOTING GUIDE)

NO. TEST (P-301) RESULT CORRECTION

10