controles electronicos del motor
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Service Training July 2002
ELECTRONIC ENGINE CONTROLS
Nigel Wilkinson
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C-9 ENGINESYSTEMS 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.
Three 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: 72 Electronic Slides
Date: 07/2002
2002 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 96-0055Cable, Communication Adapter to Machine 160-0133
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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C-9 Engine - 4 -
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TABLE OF CONTENTS
INTRODUCTION TO SYSTEMS OPERATION
Introduction ......................................................................................................................5
Lab Exercise ...................................................................................................................23
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.............................................................................................37Lab 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 ......................................................................68Speed/Timing Sensors ....................................................................................................69
Analog Sensors and Circuits ..........................................................................................72
Digital Sensors and Circuits ...........................................................................................86
Engine Shutdown Systems .............................................................................................89
Cold Starting Aids .........................................................................................................90
Data Link Circuits ..........................................................................................................93
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TABLE OF CONTENTS
CONCLUSION ....................................................................................................................96
Lab Exercise ...................................................................................................................97
SLIDE LIST .........................................................................................................................98
STUDENT HANDOUTS ....................................................................................................99
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Introduction
Manual contents
Introduction
- Use System
Operation manual
for reference
INTRODUCTION TO SYSTEMS OPERATION
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:
Introduction to Systems Operation
System Power Supplies
Electronic Control System
System Calibrations
Electronic Sensors and Systems
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
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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123456
EXHAUSTVALVES
INLETVALVES
CYLINDER AND VALVE LOCATION
FIRING ORDER 1 5 3 6 2 4
BORE 112 MM (4.4 IN)STROKE 149 MM (5.9 IN)
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Major components
ECM
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.
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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C-9 Engine - 9 -
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HEUI system
schematic
Similar to other HEUI
systems
Some system
differences
- New HEUI hydraulicpump
- No jumper tubes
- Two hydraulic oiltemperature sensors
- Water in fuel andfuel pressuresensors available
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 feddirectly 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.
See also Student Handout No. 1 for a dedicated fuel supply system
diagram.
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HEUI system
hydraulic pump
Transfer pump
mounted on rear of
HEUI pump
This view shows a cutaway of the HEUI pump.
The hydraulic pump is a high pressure, variable delivery piston pump.
This pump provides the hydraulic power to actuate the injectors.
The fuel system transfer pump is mounted on the rear of the hydraulic
pump and will deliver 450 100 kPa (65 1.5 psi).
This pump is fully described in the CD RENR1392 (described on the
previous page).
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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 schematic
Air intake heater
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 has replaced the ether aid. In
extreme cold (Arctic) conditions, it is possible to use the ether aid in
conjunction with the air intake heater. At this time however, C-9 engines
are noT being built with an ether aid.
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AIRINLET
EXHAUSTOUTLET
EXHAUSTMANIFOLD
EXHAUSTVALVE
INLETVALVE
COMPRESSORSIDE
TURBINESIDE
TURBOCHARGER
INTAKEHEATER
AIR TO AIRAFTERCOOLER
AIR INTAKE AND EXHAUST SYSTEM
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Turbocharger
components
The turbocharger is conventional and may be equipped with a Wastegate
(next page).
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AIRINLET
COMPRESSORHOUSING
COMPRESSORWHEEL BEARING
OILOUTLETPORT
TURBINEHOUSING
BEARING TURBINEWHEEL
EXHAUSTOUTLET
EXHAUST INLET
OILINLETPORT
TURBOCHARGER
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Turbocharger
wastegate
Wastegate bypasses
exhaust around the
turbocharger
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
turbocharger may develop excessive boost at rated speed and load.
The wastegate redirects a portion of the exhaust gasses past the
turbocharger which effectively limits turbocharger 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 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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PUSH ROD
LIFTER
ROCKER ARM
BRIDGE
VALVE
SPRING
VALVE SYSTEM COMPONENTS
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Air intake heater and
temperature sensor
Heater controlled by
ECM
System warns of high
air intake temperature
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.
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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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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OIL FILTER
OIL COOLER
HEUI PUMP
TOTURBOCHARGER
C-9 LUBRICATION SYSTEM
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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
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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CYLINDERHEAD
CYLINDERBLOCK
OILCOOLER
WATERPUMP RADIATOR
BYPASSHOSE
EXPANSION TANKWATER TEMPERATUREREGULATOR HOUSING
COOLING SYSTEM
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Fractured rod
Use care when
handling mating
surfaces
Fractured rod
manufacturing
process
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.
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.
The fracture process involves the following steps:
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 brokenoff, 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 reducedmachining 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 flow to rod
bearings
Related failure
analysis publications
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:
STMG Engine Bearings (SERV8001)
Engine Bearing Failure Analysis (SEBV0544)
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OIL GALLERY
MAINBEARINGS
(7)
ROD BEARINGS (6)
1234567
123456
CRANKSHAFT OIL FLOW
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Viscous crankshaft
vibration damper
The viscous crankshaft vibration damper is also used to reduce crankshaft
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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CRANKSHAFT
WEIGHT
CASE
VISCOUS VIBRATION DAMPER
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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:
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
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INSTRUCTOR NOTES
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Seven system power
supplies
SYSTEM POWER SUPPLIES
Introduction
The C-9 HEUI system has seven power supplies with various voltages as
shown.
EXTERNAL POWER SUPPLY
ECM power supply (machines) 24 Volts
Challenger Tractors and some industrial engines 12 Volts
Air intake heater (machines) 24 Volts
Service Tool Power Supply 24 Volts
INTERNAL POWER SUPPLIES
Injector and compression brake power supplies 70 Volts
Pump control valve PWM
Analog sensor power supply 5 Volts
Digital sensor power supply 8 Volts
These power supplies are described in detail in the following section.
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C-9 HEUI
SYSTEM POWER SUPPLIES
ECM
Injectors and Compression Brake
Pump Control Valve
Analog Sensors
Digital Sensors
Air Intake Heater
Service Tool
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C-9 Engine - 28 -
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24 Volt power supply
Power supply
components
Power supply
diagnostic message
J2 J1
6 DRIVERS
3 RETURNS
ENGINE RETARDER
SOLENOIDS
ECM
TIMING CALIBRATIONCONNECTOR
GROUNDBOLT
20 AMPBREAKER
MAINPOWERRELAY
KEY STARTSWITCH
24 V
20 AMP FUSE
CRANK WITHOUT INJECT PLUG
DISCONNECT SWITCH
ECM Power Supply
The power supply to the ECM and the system is provided by the 24 Volt
machine battery. The principle components in this circuit are:
- Battery
- Key Start Switch
- Main Power Relay
- 20 Amp Breaker
- 20 Amp Fuse
- Ground Bolt
- ECM Connector (P1/JI)
If the supply voltage exceeds 32.5 Volts or is less than 9.0 Volts, a
diagnostic message is logged. (See the Troubleshooting Guide for
complete details on voltage event logging.)
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C-9 Engine - 29 -
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ECM power supply
circuit
ECM switched
connection
- Energizes ECM
48
52
53
70
ECM (C-9)
24 VOLTS DC
(+)
(-)
ENGINE BLOCK
GROUND BOLT
15 AMP
CIRCUIT BREAKER
BATTERY
R
C
S
B ST
OFF
ON
KEY SWITCH
P1 J1
(-) BATTERY
(-) BATTERY
(-) BATTERY
61
63
65(+) BATTERY
(+) BATTERY
(+) BATTERY
(+) SWITCHED POWER
(+) BATTERY SUPPLY WIRES
INPUT SIGNAL WIRES TO ECM
OUTPUT SIGNAL WIRES FROM ECM
SENSOR SUPPLY VOLTAGE
SIGNAL PLUS
SIGNAL MINUS
(-) BATTERY / SENSOR RETURN
WIRE FUNCTION COLOR CODE
FUSE
20 A
DISCONNECT
SWITCH
ECM POWER SUPPLY CIRCUIT
This schematic shows the principle components for a typical C-9 power
supply circuit. Battery voltage is normally connected to the ECM.
However, an input from the key start switch turns the ECM ON.
Note the seven power connections on the ECM. There are three wires
permanently connected to the ECM battery positive and three to the
battery negative. This feature is used to reduce the amperage on the
individual pins. The actual current draw with the engine stopped with the
key off is very small.
There is also a switched connection from the battery positive (ECM
pin 70). The purpose of the "switched power" connection is to energize or
"wake up" the ECM. The key switch circuit energizes the whole ECM
from "sleep mode," which in turn activates power supplies, sensors,
actuators, injectors, data links etc.
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Battery disconnect
switch
Wiring harness
bypass
The battery disconnect may be either on the positive or the negative cable
depending on the application. The relevant Troubleshooting Guide will
show the location and the polarity of the switch.
The machine wiring harness can be bypassed for troubleshooting
purposes. These steps are described in the Troubleshooting Guide
procedure. A breakout harness can be used and is referenced under "C-9
Recommended Tooling" at the front of this book.
The supply voltage may be conveniently checked using the ET Status
Screen display.
NOTE 1: The Challenger Tractor engine and some industrial engines
may have a 12 Volt power supply.
NOTE 2: The Wire Function Color Code is shown here for the first time
and is used through the presentation.
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C-9 Engine - 31 -
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P1/P2 70 pin ECM
connectors
P1/J1 machine
interface connector
13
23
31
39
47
57
70
1
14
24
32
40
48
58
1
14
2 3 4 5 6 8 9 10 11 12 13
58 59 60 61 62 63 65 66 67 68 69 70
24
40
48
23
31
47
57
36
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