CYLINDER AND VALVE LOCATION

INLET
VALVES

EXHAUST
VALVES

FIRING ORDER 1 5 3 6 2 4

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

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-9LUBRICATIONSYSTEM

HEUIPUMP

TO
TURBOCHARGER

OILCOOLER
OIL
FILTER

COOLING SYSTEM
EXPANSION TANK
WATER TEMPERATURE
REGULATOR HOUSING
CYLINDER
HEAD

BYPASS
HOSE

CYLINDER
BLOCK

OIL
COOLER

WATER
PUMP

RADIATOR

CRANKSHAFT OIL FLOW

OIL GALLERY

MAIN
BEARINGS
(7)
7

6
6

4
4

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

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)

10

11 12 13

13

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 PASSIVE 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

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

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

PULSEWIDTHMODULATEDSIGNALS
10%

LOWIDLE0%THROTTLE

ON
DUTY =10%
CYCLE
OFF
50%

MIDRANGESPEED50%THROTTLE

ON
DUTY =50%
CYCLE
OFF
1CYCLE
90%

FULLSPEED/HIGHIDLE100%THROTTLE

ON
DUTY =90%
CYCLE
OFF
DUTYCYCLE=PERCENTOFTIMEONVSPERCENTOFTIMEOFF

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

USER DEFINED SHUTDOWN CIRCUIT

P1 J1
USER SHUTDOWN
DEVICE

59
5

ECM
USER 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

15

TRANSMISSION
ELECTRONIC CONTROL
MODULE

10
5

25
X100

R
24 V

AUT

20

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 +